Tip bonded formed laminates of film

ABSTRACT

Tip bonded formed laminates, and methods for making tip bonded formed laminates, are made from multiple layers of formed substrates made from films which are bonded together at the tips of their formed protrusions. Tip bonded laminates can be designed with greater resistance to bending, improved resilience to compression, and can be patterned for directionally oriented responses to tensile loads. Also, tip bonded formed laminates made from multiple layers of formed substrates can use their layered structure to provide better aesthetics as well as better physical properties such as improved puncture resistance. Tip bonded formed laminates can be configured with thicker portions and designed patterns, which are appealing to consumers. A tip bonded formed laminate can be made from two or more formed substrates and can be used instead of a single, thick, unformed, substrate, so the laminate can use about the same amount of material, while still providing surprising functional benefits. Tip bonded formed laminates can provide these benefits without relying on more expensive polymers and/or high concentrations of additives and offer significant improvements at a reasonable cost, when compared with unformed, single layer substrates.

FIELD

The present disclosure relates in general to laminates and in particularto laminates made from multiple layers of formed substrates made fromfilms, which are bonded together at the tips of their formedprotrusions.

BACKGROUND

Substrates such as films can serve as useful materials in many differentarticles, especially disposable consumer products; however, unformed,single layer substrates have certain limitations and disadvantages.Unformed, single layer substrates have little resistance to bending,slight resilience to compression, and generally isotropic responses totensile loads. Further, unformed, single layer substrates rely heavilyon the chemistry of their polymers and additives to provide aesthetics(e.g. opacity) and structural properties (e.g. puncture resistance). Inaddition, unformed, single layer substrates are usually thin and plain,which is unappealing to consumers.

SUMMARY

Laminates made from multiple layers of formed substrates, which arebonded together at the tips of their formed protrusions, as describedherein, offer significant improvements over unformed, single layersubstrates. Such tip bonded formed laminates can be designed withgreater resistance to bending, improved resilience to compression, andcan be patterned for directionally oriented responses to tensile loads.Also, tip bonded formed laminates made from multiple layers of formedsubstrates can use their layered structure to provide better aesthetics;for example, multiple layers of substrate can diffract and diffuse lightmore completely, resulting in increased opacity. Further, tip bondedformed laminates made from multiple layers of formed substrates can usetheir substrate formations to provide enhanced structural properties;for example, substrates with varying formations can distribute andabsorb concentrated forces more effectively, resulting in improvedpuncture resistance. In addition, such tip bonded formed laminates canbe configured with thicker portions and designed patterns, which areappealing to consumers. A tip bonded formed laminate can be made fromtwo or more formed substrates and can be used instead of a single,thick, unformed, substrate, so the laminate can use about the sameamount of material, while still providing the functional benefitsdescribed above. And, such tip bonded formed laminates can provide thesebenefits without relying on more expensive polymers and/or highconcentrations of additives. As a result, tip bonded formed laminatesmade from multiple layers of formed substrates, offer significantimprovements at a reasonable cost, when compared with unformed, singlelayer substrates.

The present invention thus relates to a laminate comprising: (a) a firstfilm having a first plurality of integrally connected, incrementallystretched, elongated corrugations disposed side-by-side, each having:(i) a first inward facing trough, which has a first trough smallestthickness; (ii) a first outward facing crest, which has a first crestsmallest thickness; and (iii) a first intermediate portion disposedbetween the first trough and the first crest, wherein the firstintermediate portion has a first intermediate smallest thickness, whichis less than the first crest smallest thickness; (b) a second filmhaving a second plurality of integrally connected, incrementallystretched, elongated corrugations disposed side-by-side, each having:(i) a second inward facing trough, which has a second trough smallestthickness; (ii) a second outward facing crest, which has a second crestsmallest thickness; and (iii) a second intermediate portion disposedbetween the second trough and the second crest, wherein the secondintermediate portion has a second intermediate thickness, which is lessthan the second crest smallest thickness. The laminate further comprisesa plurality of attachment areas, wherein each of the attachment areas isdirectly connected to a trough of a corrugation from the first pluralityto a trough of a corrugation from the second plurality.

The present invention further relates to a method of forming a laminate,the method comprising: (a) incrementally mechanically stretching a firstfilm by engaging at least a first portion of the first film with atleast a first plurality of protrusions to form within the first portiona first plurality of integrally connected, elongated corrugationsdisposed side-by-side, each having a trough and a crest; and (b)incrementally mechanically stretching a second film by engaging at leasta second portion of the second film with at least a second plurality ofprotrusions to form within the second portion a second plurality ofintegrally connected, elongated corrugations disposed side-by-side, eachhaving a trough and a crest. While the portion of the first film isengaged with the first plurality of protrusions, and while the portionof the second film is engaged with the second plurality of protrusions,the first plurality of corrugations are directly connected to the secondplurality of corrugations at a plurality of attachment areas, to formthe laminate.

The present invention further relates to a machine for forming alaminate, the machine comprising: a machine direction and a crossdirection; a first web supply apparatus and a second web supplyapparatus, which are the only web supply apparatus of the machine. Themachine further comprises a first rotating patterning roll, which isdownstream from the first web supply apparatus and having a firstplurality of rigid, elongated protrusions, each with a tip, and a secondrotating patterning roll, which is downstream from the first web supplyapparatus and having a second plurality of rigid, elongated protrusions,each with a tip. The first roll is positioned with respect to the secondroll such that, as the rolls rotate, the tips of the first plurality arealways unmated with the tips of the second plurality, and the tips ofthe first plurality come within joining proximity of from 0 to 5millimeters of the tips of the second plurality.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a partially broken top view of a portion of alaminate with patterned areas having corrugations oriented in a machinedirection.

FIG. 2 illustrates a partially broken top view of a portion of alaminate with patterned areas having corrugations oriented in a crossdirection.

FIG. 3A illustrates a top view of a patterned area having corrugationsoriented in a machine direction with an overall shape like a rhombus.

FIG. 3B illustrates a top view of a patterned area having corrugationsoriented in a cross direction with an overall shape like a rhombus.

FIG. 3C illustrates a top view of a patterned area having corrugationsoriented in a machine direction with an overall shape like a square.

FIG. 3D illustrates a top view of a patterned area having corrugationsoriented in a cross direction with an overall shape like a square.

FIG. 3E illustrates a top view of a patterned area having corrugationsoriented in a machine direction with an overall shape like a circle.

FIG. 3F illustrates a top view of a patterned area having corrugationsoriented in a cross direction with an overall shape like a circle.

FIG. 4A illustrates an enlarged end view of a laminate with a patternedarea formed by first and second substrates, which are films havingcorrugated and uncorrugated portions, wherein within the corrugatedportion troughs of the films are directly connected at narrow attachmentareas, and within the uncorrugated portions the films are offset.

FIG. 4B is a modified version of the laminate of FIG. 4A, wherein thefilms are directly connected at wide attachment areas.

FIG. 5A illustrates an enlarged end view of a modified version of thelaminate of FIG. 4A, with outer films joined to the first and secondfilms.

FIG. 5B illustrates an enlarged end view of a modified version of thelaminate of FIG. 4B, with outer films joined to the first and secondfilms.

FIG. 6A illustrates an enlarged end view of a laminate with a patternedarea formed by first and second films having corrugated and uncorrugatedportions, wherein within the corrugated portion troughs of the films aredirectly connected at narrow attachment areas, and within theuncorrugated portions the films are adjacent.

FIG. 6B is a modified version of the laminate of FIG. 6A, wherein thefilms are directly connected at wide attachment areas.

FIG. 7A illustrates an enlarged end view of a modified version of thelaminate of FIG. 6A, with outer films joined to the first and secondfilms.

FIG. 7B illustrates an enlarged end view of a modified version of thelaminate of FIG. 6B, with outer films joined to the first and secondfilms.

FIG. 8 shows a flow diagram for methods of making a laminate withpatterned areas.

FIG. 9 is an assembly diagram illustrating a machine with fourpatterning rolls having protrusions oriented in the machine direction,for incrementally stretching first and second substrates and for joiningthe substrates together to form a tip bonded formed laminate with offsetuncorrugated portions.

FIG. 10A illustrates an enlarged partial cross-sectional view of twomating patterning rolls from the machine of FIG. 9, wherein the rollsare incrementally stretching a first substrate.

FIG. 10B illustrates an enlarged partial cross-sectional view of twomating patterning rolls from the machine of FIG. 9, wherein the rollsare incrementally stretching a second substrate.

FIG. 11A illustrates an enlarged partial cross-sectional view of thefirst substrate engaged with the first patterning roll from the machineof FIG. 9, wherein an adhesive is applied to troughs of corrugations ofthe first substrate.

FIG. 11B illustrates an enlarged partial cross-sectional view of thesecond substrate engaged with the second patterning roll from themachine of FIG. 9.

FIG. 11C illustrates a partial outside view of the first substrate ofFIG. 11A.

FIG. 12A illustrates an enlarged partial cross-sectional view in themachine direction of the troughs of the corrugations from the firstsubstrate being adhesively connected to the troughs of the corrugationsfrom the second substrate, while the substrates are engaged withpatterning rolls from the machine of FIG. 9, to form the tip bondedformed laminate of FIG. 9.

FIG. 12B illustrates an enlarged partial cross-sectional view in thecross direction of a trough of the corrugations from the first substratebeing adhesively connected to a trough of the corrugations from thesecond substrate, while the substrates are engaged with patterning rollsfrom the machine of FIG. 9, to form the tip bonded formed laminate ofFIG. 9.

FIG. 12C illustrates a further enlarged portion of the view from FIG.12B.

FIG. 13 is an assembly diagram illustrating a machine with fourpatterning rolls having protrusions oriented in the cross direction, forincrementally stretching first and second substrates and for joining thesubstrates together to form a tip bonded formed laminate with offsetuncorrugated portions.

FIG. 14 is an assembly diagram illustrating a machine with fourpatterning rolls having protrusions oriented in the machine direction,for incrementally stretching first and second substrates and for joiningthe substrates together to form a tip bonded formed laminate withadjacent uncorrugated portions.

FIG. 15A illustrates an enlarged partial cross-sectional view of twomating patterning rolls from the machine of FIG. 14, wherein the rollsare incrementally stretching a first substrate.

FIG. 15B illustrates an enlarged partial cross-sectional view of twomating patterning rolls from the machine of FIG. 14, wherein the rollsare incrementally stretching a second substrate.

FIG. 16A illustrates an enlarged partial cross-sectional view of thefirst substrate engaged with the first patterning roll from the machineof FIG. 14, wherein an adhesive is applied to troughs of corrugations ofthe first substrate and to the adjacent uncorrugated portions.

FIG. 16B illustrates an enlarged partial cross-sectional view of thesecond substrate engaged with the second patterning roll from themachine of FIG. 14.

FIG. 17 illustrates an enlarged partial cross-sectional view in themachine direction of the troughs of the corrugations from the firstsubstrate being adhesively connected to the troughs of the corrugationsfrom the second substrate and the uncorrugated portions of the firstsubstrate being adhesively connected to the uncorrugated portions of thesecond substrate, while the substrates are engaged with patterning rollsfrom the machine of FIG. 14, to form the tip bonded formed laminate ofFIG. 14.

FIG. 18 is an assembly diagram illustrating a machine with fourpatterning rolls having protrusions oriented in the cross direction, forincrementally stretching first and second substrates and for joining thesubstrates together to form a tip bonded formed laminate with adjacentuncorrugated portions.

FIG. 19 is an enlarged cross-sectional view of a portion of a laminatewith a patterned area formed by first and second films along with outerfilms, wherein the laminate includes benefit agents disposed atlocations within the laminate.

FIG. 20A is an enlarged end view of a portion of an exemplary laminate,which illustrates the extent of a crest.

FIG. 20B is an enlarged end view of a portion of an exemplary laminate,which illustrates the extent of a trough.

FIG. 21 is an enlarged end view of a portion of an exemplary laminate,which illustrates various measurements.

FIG. 22 is an exemplary drawstring type trash bag, which can includetip-bonded laminates of the present disclosure.

FIG. 23 is an exemplary tie type trash bag, which can include tip-bondedlaminates of the present disclosure.

DETAILED DESCRIPTION

Tip bonded formed laminates of the present disclosure can be made frommultiple layers of formed substrates, such as films, and can offersignificant improvements over unformed, single layer substrates,including: greater resistance to bending, improved resilience tocompression, directionally oriented responses to tensile loads, betteraesthetics, enhanced structural properties, thicker portions, anddesigned patterns, without relying on more expensive polymers and/orhigh concentrations of additives; as a result, such tip bonded formedlaminates offer significant improvements at a reasonable cost, whencompared with unformed, single layer substrates.

Throughout the figures, the machine direction is shown as MD and thecross direction is shown as CD; a labeled arrow indicates theorientation of the labeled direction with respect to the figure, while alabeled X indicates that the labeled direction is orthogonal (i.e. into)to the page. And, throughout the figures, laminates are illustrated withpatterned areas having particular numbers of corrugations, however, forany patterned area disclosed herein, any number of corrugations may beused; as examples, a patterned area can have 2-100 corrugations, or anynumber of corrugations between 2 and 100, or any range formed by any ofthese values such as 2-50 corrugations, 3-40 corrugations, 4-30corrugations, 5-20 corrugations, etc.

FIG. 1 illustrates a partially broken top view of a portion of alaminate 100 with patterned areas having corrugations orientedlengthwise in a machine direction. The laminate 100 is made of a firstsubstrate 110 on the top and a second substrate 120 (shown in the brokenportion) on the bottom of the laminate 100. The first substrate 110 isdirectly connected to the second substrate 120 at a plurality ofattachment areas shown by straight line segments, which are parallelwith the machine direction. The first substrate 110 and the secondsubstrate 120 each include corrugated portions disposed between adjacentattachment areas and uncorrugated portions disposed outside of theattachment areas. A plurality of attachment areas forms the patternedarea 104, which has an overall shape 104-os like a rhombus; however, invarious embodiments, for any laminate disclosed herein, the laminate mayinclude patterned areas having any overall shape disclosed herein orknown in the art of patterned substrates. The attachment areas that formthe patterned area 104 are repeating over the laminate 100, to form aplurality of discrete patterned areas, each with the same configuration,including the same overall shape; however, in various embodiments, forany laminate disclosed herein, the laminate may include two or moredifferent patterned areas, which may or may not repeat in a pattern overthe laminate. The patterned areas are arranged in repeating lineararrays, which form a tessellating pattern, wherein the patterned areasare separated from each other by linear pathways 106, disposed betweenthe patterned areas, and wherein the pathways are formed by theuncorrugated portions of the substrates. Each of the pathways has anoverall width 106-ow, which is substantially uniform. For the laminate100 and for any laminate disclosed herein, any of the pathways can havean overall width of 1-100 millimeters, or any integer value between 1and 100 millimeters, or any range formed by any of these values, such as1-50 millimeters, 1-20 millimeters, 1-10 millimeters, etc; also part,parts, or all of any pathway disposed between patterned areas can have avariable overall width and/or can be curved.

In various embodiments, the laminates disclosed herein can exhibitdirectionally variable bending stiffness. The attachment areas can actlike beams in their direction of orientation, providing directionalstrengthening of the connected substrates. The pathways may or may notact like hinges, depending on their configuration within the laminate.As an example, a laminate may have a first direction (parallel with theoverall planar orientation of the laminate) having a lowest bendingstiffness for the laminate, and a second direction (also parallel withthe overall planar orientation of the laminate), which differs from thefirst direction (e.g. is perpendicular to the first direction), having ahighest bending stiffness for the laminate, wherein the highest bendingstiffness is 50-10,000% greater than the lowest bending stiffness, orany integer value between 50% and 5,000%, or any range formed by any ofthese values, such as 50-2,000%, 75-1,000%, 100-500%, etc.

In the embodiment of FIG. 1, since all of the attachment areas of thelaminate 100 are oriented in the machine direction, the attachment areasprovide the laminate 100 with a relatively higher bending stiffness inthe machine direction, and a relatively lower bending stiffness in thecross direction. And, in the embodiment of FIG. 1, since the pathways106 are linear pathways disposed in parallel, the pathways 106 providethe laminate 100 with relatively lower bending stiffness at angles takenperpendicular to the pathways.

The laminate 100 can be configured according to any laminate describedherein, such as the laminate 400-a of FIG. 4A, the laminate 400-b ofFIG. 4B, the laminate 600-a of FIG. 6A, or the laminate 600-b of FIG.6B, or any alternative laminate embodiment disclosed herein or known inthe art. In various embodiments, the laminate 100 can be modified byadding first and/or second outer substrates, such as in the laminate500-a of FIG. 5A, the laminate 500-b of FIG. 5B, the laminate 700-a ofFIG. 7A, or the laminate 700-b of FIG. 7B. The laminate 100 can be madeaccording to the method 800 of FIG. 8, or made according to anyalternative method embodiment disclosed herein. The laminate 100 can bemade using the machine 902 of FIG. 9, the machine 1402 of FIG. 14, ormade using any alternative machine embodiment disclosed herein. Invarious embodiments, part, parts, or all of the laminate 100 or anylaminate disclosed herein can be modified such that some or all of thecorrugations are oriented at a positive or negative angle from 1-89degrees with respect to the machine direction, or any integer valuebetween 1 and 89 degrees, or any range formed by any of these values,such as 1-60 degrees, 1-45 degrees, 1-30 degrees, 30-89 degrees, 45-89degrees, 60-89 degrees, 30-60 degrees, 40-50 degrees, etc.

FIG. 2 illustrates a partially broken top view of a portion of alaminate 200 with patterned areas having corrugations orientedlengthwise in the cross direction. The laminate 200 is made of a firstsubstrate 210 and a second substrate 220, with discrete patterned areasincluding patterned area 204 with an overall shape like a rhombus,repeating over the laminate 200, separated from each other by pathways206. The laminate 200 of FIG. 2 is configured in the same way as thelaminate 100 of FIG. 1, with like-numbered elements configured in thesame way, except as described differently below. The first substrate 210and the second substrate 220 are directly connected at a plurality ofattachment areas shown by line segments, which are parallel with thecross direction. Since all of the attachment areas of the laminate 200are oriented in the cross direction, the attachment areas provide thelaminate 200 with a relatively higher bending stiffness in the crossdirection, and since the pathways 206 are linear pathways disposed inparallel, the pathways 206 provide the laminate 200 with relativelylower bending stiffness at angles taken perpendicular to the pathways.The laminate 200 can be configured or modified in any of the ways thatthe laminate 100 of FIG. 1 can be configured or modified. The laminate200 can be made according to the method 800 of FIG. 8, or made accordingto any alternative method embodiment disclosed herein. The laminate 200can be made using the machine 1302 of FIG. 13, the machine 1802 of FIG.18, or made using any alternative machine embodiment disclosed herein.

FIGS. 3A-3F illustrate top views of exemplary patterned areas havingattachment areas that form corrugations oriented in various directions,and patterned areas with various overall shapes. FIG. 3A illustrates apatterned area 304-a having corrugations oriented lengthwise in themachine direction and an overall shape like a rhombus, as shown with thepatterned area 104 in the laminate 100 of FIG. 1. FIG. 3B illustrates apatterned area 304-b having corrugations oriented lengthwise in thecross direction, and an overall shape like a rhombus, as shown with thepatterned area 204 in the laminate 200 of FIG. 2. FIG. 3C illustrates apatterned area 304-c having corrugations oriented lengthwise in themachine direction, and an overall shape like a square, which can be usedfor any patterned area of any laminate disclosed herein. FIG. 3Dillustrates a patterned area 304-d having corrugations orientedlengthwise in a cross direction, and an overall shape like a square,which can be used for any patterned area of any laminate disclosedherein. In various embodiments, a laminate can have patterned areas withan overall shape like a rectangle, trapezoid, triangle, pentagon,hexagon, heptagon, octagon, or any other regular or irregular polygonhaving any number of sides. FIG. 3E illustrates a patterned area 304-ehaving corrugations oriented lengthwise in a machine direction, and anoverall shape like a circle. FIG. 3F illustrates a patterned area 304-fhaving corrugations oriented lengthwise in a cross direction, and anoverall shape like a circle. In various embodiments, a laminate can havepatterned areas with an overall shape like an oval, ellipse, or anyother rounded shape having any configuration. Any of the overall shapesof the exemplary patterned areas of FIGS. 3A-3F or any other overallshape disclosed herein or known in the art can be used for any patternedarea in any laminate disclosed herein, in any workable combination.

FIGS. 4A-7B illustrate enlarged end views of laminates formed, at leastin part, by a corrugated portion of a first substrate directly connectedto a corrugated portion of a second substrate. These laminates areillustrated with patterned areas having a particular number ofcorrugations, however any number of corrugations may be used, includingany number disclosed herein, for any embodiment of laminate disclosedherein. These laminates are illustrated with corrugations havingparticular, uniform proportions, however, these particular shapes arenot required, and the uniformity and/or proportions of part, parts, orall of one or more of any of the corrugations may vary within anypatterned area or between patterned areas in any substrate and/orbetween any substrates, for any embodiment of laminate disclosed herein.Any of the embodiments of FIGS. 4A-7B can be used to form a tip bondedformed laminate with some or all of the corrugations oriented in anyconvenient direction for the laminate, such as the machine direction,the cross direction, or any positive or negative angle from 1-89 degreeswith respect the machine direction and/or the cross direction.

FIGS. 4A-4B, 5A-5B, 6A-6B, and 7A-7B illustrate embodiments wherein thelaminates are formed, at least in part, by a corrugated portion of afirst film directly connected to a corrugated portion of a second film.For ease of illustration, each substrate is illustrated as a smooth,continuous film having a particular uniform thickness, however theseparticular shapes are not required, and the smoothness, continuity,and/or thickness of part, parts, or all of one or more of any of thefilm substrates may vary within any patterned area and/or betweenpatterned areas in any substrate and/or between any substrates, in anyway disclosed herein and/or in any way known in the art, for anyembodiment of laminate disclosed herein. Although each of theseembodiments describes and illustrates a first film directly connected toa second film, in various embodiments, some or all of the connectionsbetween the films may be indirect connections, which include one or moreintermediate materials (in addition to any adhesive used for making theconnection). Also, any of the embodiments disclosed herein can bemodified to include one or more intermediate substrates (e.g. filmlayers), disposed between the first film and the second film.

FIG. 4A illustrates an enlarged end view of a laminate 400-a formed by afirst substrate, which is a first film 410-a and a second substrate,which is a second film 420-a. The laminate 400-a has a discretepatterned area 404-a surrounded by pathways 406-a. The laminate 400-aalso has a central corrugated portion 401-a and uncorrugated portions408-la and 408-2 a disposed on either side of the corrugated portion401-a. Within the corrugated portion 401-a, the first film 410-a isdirectly connected to the second film 420-a at a plurality of long (intothe page) but relatively narrow (across the page) attachment areas405-a. The corrugated portion 401-a forms the patterned area 404-a.Within the uncorrugated portions 408-la and 408-2 a, the first film410-a and the second film 420-a are not connected, but are offset fromeach other by offset distance 419-oda. The uncorrugated portions 408-1 aand 408-2 a of the films 410-a and 420-a form the pathways 406-a betweenthe patterned area 404-a and other patterned areas of the laminate400-a.

In the corrugated portion 401-a, the first film 410-a has a firstplurality of corrugations 411-a, with a shape like a repeating wavehaving troughs 412-a and crests 413-a. In the first film 410-a of FIG.4A, the corrugations 411-a have the same wavelength and amplitude,however, in various embodiments, for any laminate disclosed herein, afirst substrate may have a patterned area with corrugations havingvarying wavelength and/or amplitude. The corrugations 411-a are disposedlinearly, in parallel, side-by-side and are integrally connected to eachother since they are formed from the same material, which is the firstfilm 410-a. However, in various embodiments, for any laminate disclosedherein, some or all of the corrugations in a patterned area may not becompletely parallel with each other, but may have overall orientations(taken end-to-end) that are 1-15 degrees out of parallel with eachother, or out of parallel by any integer value between 1 and 15 degrees,or by any range formed by any of these values, such as 1-10 degrees, 1-5degrees, 1-2 degrees, etc. Each of the corrugations 411-a isincrementally stretched, such that the troughs 412-a and the crests413-a are permanent features of the first film 410-a separated byportions of the first film 410-a that are extended and thinned by asolid state formation process. Each of the corrugations 411-a iselongated since it has an overall length (into to the page) that isgreater than its overall width. In various embodiments, for anypatterned area of any laminate disclosed herein, one, or some, or all ofthe corrugations may be continuous with an overall length that continuesall the way along the laminate and/or one, or some, or all of thecorrugations may be discrete with an overall length that does notcontinue all the way along the laminate. Table 1, set forth below,describes nine embodiments of laminate, which represent variouscombinations of corrugation lengths and corrugations orientations forthe first substrate and the second substrate, which are contemplated asapplicable to any laminate described herein. In Table 1, “angled at α”means that an elongated corrugation has an overall orientation that isoriented at any angle α of 1-89 degrees between the machine directionand the cross direction.

TABLE 1 corrugations of first substrate corrugations of second substrate# length orientation length orientation 1 continuous machine directioncontinuous machine direction 2 continuous machine direction discretemachine direction 3 discrete machine direction discrete machinedirection 4 continuous cross direction continuous cross direction 5continuous cross direction discrete cross direction 6 discrete crossdirection discrete cross direction 7 continuous angled at α continuousangled at α 8 continuous angled at α discrete angled at α 9 discreteangled at α discrete angled at α

In various embodiments, for any patterned area of any laminate disclosedherein, some or all of the corrugations may have a same overall lengthand/or some or all of the corrugations may have differing overalllengths; the overall lengths of the corrugations may be selected suchthat that the patterned area has a particular overall shape (when viewedfrom a top view), such as any overall shape disclosed herein or known inthe art.

The second film 420-a has the same configuration as the first film410-a, except that the second film 420-a is configured and oriented as amirrored version of the first film 410-a, mirrored around an imaginaryhorizontal line disposed along the bottoms of the troughs 412-a of thefirst film 410-a. So, in the corrugated portion 401-a, the second film420-a has a second plurality of wave-like corrugations 421-a, which arealso integrally connected, discrete, elongated, incrementally stretched,and disposed linearly, in parallel, side-by-side, with troughs 422-a andcrests 423-a. Due to the mirrored configuration, the corrugations 421-ahave the same wavelength and amplitude as the corrugations 411-a, andall of the troughs 412-a and 422-a face inward while all of the crests413-a and 423-a face outward. The first film 410-a is aligned bothside-to-side and lengthwise (into the page) with the second film 420-aand is attached to the second film 420-a by a plurality of attachmentareas 405-a. Since the attachment areas 405-a attach the first film410-a to the second film 420-a, the corrugations 411-a have the sameoverall lengths as the corrugations 421-a.

In various embodiments, for any patterned area of any laminate disclosedherein, a second substrate may not be a mirrored version of the firstsubstrate, but may differ from the first substrate in any way disclosedherein; in particular, the corrugations of the second substrate maydiffer in wavelength and/or amplitude from the corrugations of the firstsubstrate. Table 2, set forth below, describes nine embodiments oflaminate, which represent various combinations of corrugationwavelengths and amplitudes for the first substrate and the secondsubstrate, which are contemplated as applicable to any laminatedescribed herein. In Table 2, “same,” “smaller,” and “larger” are usedas terms of relative size; same means corrugations having an equivalentsize; smaller means corrugations having a relatively lesser size; largermeans corrugations having a relatively greater size; the corrugations ofeither substrate may otherwise have any size disclosed herein or knownin the art.

TABLE 2 corrugations of corrugations of first substrate second substrate# wavelength amplitude wavelength amplitude 1 same same same same 2smaller same larger same 3 larger same smaller same 4 same smaller samelarger 5 smaller smaller larger larger 6 larger smaller smaller larger 7same larger same smaller 8 smaller larger larger smaller 9 larger largersmaller smaller

The plurality of attachment areas 405-a directly connects the troughs412-a with the troughs 422-a such that each of the troughs 412-a isdirectly connected to a single one of the troughs 422-a, and each of thetroughs 422-a is directly connected to a single one of the troughs412-a; however, in various embodiments, for any patterned area of anylaminate disclosed herein, multiple troughs from the corrugations of thefirst substrate may be directly connected to a single trough from acorrugation of the second substrate. Any of the attachment areasdisclosed herein can be formed by one or more adhesives and/or fusedportions, which extend continuously or discontinuously along part orparts of about all, approximately all, substantially all, nearly all, orall of either or both of the connected troughs; any suitable adhesivefor connecting films may be used, such as 5100-N ZP (Full Care),available from H.B. Fuller of Saint Paul, Minn., United States ofAmerica; the films may be fused together by the application of heatand/or pressure to the films as they are held in contact, in any wayknown in the art. In the embodiment of FIG. 4A, the corrugations 411-aof the first film 410-a are only attached to the corrugations 421-a ofthe second film 420-a at the plurality of attachment areas 405-a.Further, in the embodiment of FIG. 4A, the first film 410-a is onlyattached to the second film 420-a at the plurality of attachment areas405-a; however in various embodiments, for any laminate disclosedherein, the first substrate and the second substrate may be joinedtogether in various ways at one or more other locations on the laminate,such as locations in uncorrugated portions.

The first film 410-a changes from a wavelike shape in the corrugations411-a of the corrugated portion 401-a to a flat shape in theuncorrugated portions 408-la and 408-2 a; these changes in shape occurat a first transition 417-la on one side of the corrugated portion 401-aand at a second transition 417-2 a on the other side of the corrugatedportion 401-a. Similarly, the second film 420-a changes from a wavelikeshape in the corrugations 421-a of the corrugated portion 401-a to aflat shape in the uncorrugated portions 408-la and 408-2 a; thesechanges in shape occur at a first transition 427-la on one side of thecorrugated portion 401-a and at a second transition 427-2 a on the otherside of the corrugated portion 401-a. The first transitions 417-la and427-la are offset from each other, so, in the uncorrugated portion 408-1a, the first film 410-a and the second film 420-a are offset from eachother; the second transitions 417-2 a and 427-2 a are also offset fromeach other, so, in the uncorrugated portion 408-2 a, the first film410-a and the second film 420-a are offset from each other; however, invarious embodiments, for any laminate disclosed herein, the substratesmay be proximate to each other and/or in contact with each other at oneor more other locations on the laminate, in the uncorrugated portions.

FIG. 4B illustrates an enlarged end view of a laminate 400-b formed by afirst substrate, which is a first film 410-b and a second substrate,which is a second film 420-b. The laminate 400-b of FIG. 4B isconfigured in the same way as the laminate 400-a of FIG. 4A, withlike-numbered elements configured in the same way, except that the firstfilm 410-b and the second film 420-b are directly connected at aplurality of attachment areas 405-b, which are relatively wider (acrossthe page) than the attachment areas 405-a of the laminate 400-a. Inalternative embodiments, the laminate 400-b can be modified in any ofthe ways that the laminate 400-a of FIG. 4A can be modified.

FIG. 5A illustrates an enlarged end view of a laminate 500-a formed by afirst substrate, which is a first film 510-a, a second substrate, whichis a second film 520-a, a third substrate, which is a third film 540-1a, and a fourth substrate, which is a fourth film 540-2 a. The laminate500-a of FIG. 5A is configured in the same way as the laminate 400-a ofFIG. 4A, with like-numbered elements configured in the same way, exceptthat the laminate 500-a includes the third film 540-1 a, which is anouter film joined to the outward facing crests of the corrugations ofthe first film 510-a; the third film 540-la can be joined to the firstfilm 510-a directly or indirectly in any way described herein and/orknown in the art. The laminate 500-a includes the fourth film 540-2 a,which is an outer film joined to the outward facing crests of thecorrugations of the second film 520-a; the fourth film 540-2 a can bejoined to the second film 520-a directly or indirectly in any waydescribed herein and/or known in the art. In alternative embodiments,the laminate 500-a can be modified in any of the ways that the laminate400-a of FIG. 4A can be modified. For any laminate with outersubstrates, disclosed herein, part, parts, or all of either or both ofthe outer substrates may be omitted from the laminate and/or othersubstrates may be added in place of part, parts, or all of either orboth of the outer substrates, in any workable combination. Inalternative embodiments, for any laminate disclosed herein, one or moreadditional substrates (e.g. films or nonwovens) and/or structures, inany form disclosed herein or known in the art, may be added to thelaminate.

FIG. 5B illustrates an enlarged end view of a laminate 500-b formed by afirst substrate, which is a first film 510-b, a second substrate, whichis a second film 520-b, a third substrate, which is a third film 540-1b, and a fourth substrate, which is a fourth film 540-2 b. The laminate500-b of FIG. 5B is configured in the same way as the laminate 400-b ofFIG. 4B, with like-numbered elements configured in the same way, exceptas described differently below. The laminate 500-b includes the thirdfilm 540-1 b, which is an outer film joined to the outward facing crestsof the corrugations of the first film 510-b and also joined to theuncorrugated portions 508-la and 508-2 a of the first film 510-a; thethird film 540-1 b can be joined to the first film 510-b directly orindirectly in any way described herein and/or known in the art. Thelaminate 500-b includes the fourth film 540-2 b, which is an outer filmjoined to the outward facing crests of the corrugations of the secondfilm 520-b and also joined to the uncorrugated portions 508-la and 508-2a of the second film 520-a; the fourth film 540-2 b can be joined to thesecond film 520-b directly or indirectly in any way described hereinand/or known in the art. In alternative embodiments, the laminate 500-acan be modified in any of the ways that the laminate 500-a of FIG. 5Acan be modified.

FIG. 6A illustrates an enlarged end view of a laminate 600-a formed by afirst substrate, which is a first film 610-a, and a second substrate,which is a second film 620-a. The laminate 600-a of FIG. 6A isconfigured in the same way as the laminate 400-a of FIG. 4A, withlike-numbered elements configured in the same way, except as describeddifferently below. The first transitions 617-la and 627-la are adjacentto each other, so, in the uncorrugated portion 608-1 a, the first film610-a and the second film 620-a are adjacent to each other, are incontact with each other, and are directly or indirectly joined to eachother; the second transitions 617-2 a and 627-2 a are also adjacent toeach other and in contact with each other, so, in the uncorrugatedportion 608-2 a, the first film 610-a and the second film 620-a areadjacent to each other, are in contact with each other, and are directlyor indirectly joined to each other. In any embodiment of laminatedisclosed herein, in the uncorrugated portions, the first substrate andthe second substrate can be joined together in any convenient way (e.g.directly connected by adhesive at one or more locations); however, invarious embodiments, the first substrate and the second substrate may beproximate to each other and/or not in contact with each other and/or notjoined to each other at one or more locations in the uncorrugatedportions. In alternative embodiments, the laminate 600-a can be modifiedin any of the ways that the laminate 400-a of FIG. 4A can be modified.

FIG. 6B illustrates an enlarged end view of a laminate 600-b formed by afirst substrate, which is a first film 610-b and a second substrate,which is a second film 620-b. The laminate 600-b of FIG. 6B isconfigured in the same way as the laminate 600-a of FIG. 6A, withlike-numbered elements configured in the same way, except that the firstfilm 610-b and the second film 620-b are directly connected at aplurality of attachment areas 605-b, which are relatively wider (acrossthe page) than the attachment areas 605-a of the laminate 600-a. Inalternative embodiments, the laminate 600-b can be modified in any ofthe ways that the laminate 600-a of FIG. 6A can be modified.

FIG. 7A illustrates an enlarged end view of a laminate 700-a formed by afirst substrate, which is a first film 710-a, a second substrate, whichis a second film 720-a, a third substrate, which is a third film 740-1a, and a fourth substrate, which is a fourth film 740-2 a. The laminate700-a of FIG. 7A is configured in the same way as the laminate 600-a ofFIG. 6A, with like-numbered elements configured in the same way, exceptthat the laminate 700-a includes the third film 740-1 a, which is anouter film joined to the outward facing crests of the corrugations ofthe first film 710-a; the third film 740-la can be joined to the firstfilm 710-a directly or indirectly in any way described herein and/orknown in the art. The laminate 700-a includes the fourth film 740-2 a,which is an outer film joined to the outward facing crests of thecorrugations of the second film 720-a; the fourth film 740-2 a can bejoined to the second film 720-a directly or indirectly in any waydescribed herein and/or known in the art. In alternative embodiments,the laminate 700-a can be modified in any of the ways that the laminate600-a of FIG. 6A can be modified.

FIG. 7B illustrates an enlarged end view of a laminate 700-b formed by afirst substrate, which is a first film 710-b, a second substrate, whichis a second film 720-b, a third substrate, which is a third film 740-1b, and a fourth substrate, which is a fourth film 740-2 b. The laminate700-b of FIG. 7B is configured in the same way as the laminate 600-b ofFIG. 6B, with like-numbered elements configured in the same way, exceptas described differently below. The laminate 700-b includes the thirdfilm 740-1 b, which is an outer film joined to the outward facing crestsof the corrugations of the first film 710-b and also joined to theuncorrugated portions 708-la and 708-2 a of the first film 710-a; thethird film 740-1 b can be joined to the first film 710-b directly orindirectly in any way described herein and/or known in the art. Thelaminate 700-b includes the fourth film 740-2 b, which is an outer filmjoined to the outward facing crests of the corrugations of the secondfilm 720-b and also joined to the uncorrugated portions 708-la and 708-2a of the second film 720-a; the fourth film 740-2 b can be joined to thesecond film 720-b directly or indirectly in any way described hereinand/or known in the art. In alternative embodiments, the laminate 700-acan be modified in any of the ways that the laminate 700-a of FIG. 7Acan be modified.

For any of the laminates disclosed herein, the corrugations can have anyconvenient sizes and proportions, including any of the following. Any ofthe corrugations can have a wavelength of 0.5-5 millimeters, or anyvalue between 0.5 and 5 millimeters in increments of 0.5 millimeters, orany range formed by any of these values, such as 1-4 millimeters, 1-3millimeters, 1-2 millimeters, etc. Any of the corrugations can have anamplitude of 0.1-10 millimeters, or any value between 0.1 and 10millimeters in increments of 0.1 millimeters, or any range formed by anyof these values, such as 0.1-5 millimeters, 1-4 millimeters, 1-2millimeters, etc. Any of the corrugations can have a ratio of amplitudeto wavelength that is from 0.2 to 10 or any value in increments of 0.1between 0.2 and 10, or any range formed by any of these values, such as0.5-7.5, 0.7-5, 1-3, etc. Any of the attachment areas betweencorrugations can have an overall width of 0.1-5 millimeters, or anyvalue between 0.1 and 5 millimeters in increments of 0.1 millimeters, orany range formed by any of these values, such as 0.1-3 millimeters,0.2-1 millimeters, 0.2-0.5 millimeters, etc. Any of the corrugations canhave a ratio of wavelength to overall width of an attachment area thatis from 1.1 to 100 or any value in increments of 0.1 between 1 and 100,or any range formed by any of these values, such as 1-80, 5-65, 25-50,etc. Any of the corrugations can have an overall length of 1-10,000millimeters, or any integer value between 1 and 10,000 millimeters, orany range formed by any of these values, such as 1-1,000 millimeters,1-100 millimeters, 2-60 millimeters, 3-50 millimeters, 4-40 millimeters,5-30 millimeters, etc.

Any of the tip bonded formed laminates disclosed herein can be made fromsubstrates (e.g. films) of various chemistries, including one or more ofany kind of polymeric material such as polyethylene (e.g. Linear lowdensity PE, Low Density PE, and High Density PE), polypropylene, nylon,ethyl vinyl acetate, and/or any other polymer suitable for makingsubstrates, along with any additives (e.g. pigments/colorants) and/ormodifiers (e.g. titanium dioxide) known in the art of substrate-making,in any combination (e.g. homopolymers, copolymers, blends, etc.) and inany form (e.g. single layers, laminates, layered structures,coextrusions, etc.) made by any kind of substrate-making process. Any ofthe tip bonded formed laminates disclosed herein can be made fromsubstrates of various thicknesses, such substrates having an overallthickness of 5-250 microns (0.2-10 mils), or any integer value between 5and 250 microns, or any range formed by any of these values, such as5-100 microns (0.2-3.9 mils), 10-50 microns (0.39-2 mils), 10-30 microns(0.39-1.4 mils), etc.

For any of the laminates disclosed herein, the first substrate, thesecond substrate (as well as either or both outer substrates, ifpresent), may be the same or may be different in any way known in theart; for example, such differences may include differences in color,opacity, thickness, mechanical properties (e.g. elasticity,inelasticity, extensibility, inextensibility, ductility or brittleness,puncture resistance, etc.), polymeric type, presence of additives, useof modifiers, etc., in any workable combination.

FIG. 8 shows a flow diagram 800 for methods of making a laminate withpatterned areas, as described herein. The method 800 includes a firststep 801 of incrementally mechanically stretching a first substrateusing a first patterning surface to form first corrugations. The method800 includes a second step 802 of incrementally mechanically stretchinga second substrate using a second patterning surface to form secondcorrugations. The method 800 includes a third step 803, performed whilethe first substrate is engaged with the first patterning surface andwhile the second substrate is engaged with the second patterningsurface, wherein the third step 803 includes directly connecting thecorrugations of the first substrate to the corrugations of the secondsubstrate to form the tip bonded formed laminate.

The incremental stretching and joining of the substrates in the method800 can be performed using the machine 902 of FIG. 9, the machine 1302of FIG. 13, the machine 1402 of FIG. 14, the machine 1802 of FIG. 18, orany alternative machine embodiment disclosed herein. The laminateresulting from the method 800 can be configured according to anylaminate described herein, such as the laminate 400-a of FIG. 4A, thelaminate 400-b of FIG. 4B, the laminate 400-c of FIG. 4C, the laminate400-d of FIG. 4D, the laminate 600-a of FIG. 6A, the laminate 600-b ofFIG. 6B, the laminate 600-c of FIG. 6C, the laminate 600-d of FIG. 6D,or any alternative embodiment of any of these, as disclosed herein. Invarious alternative embodiments, the process 800 can be modified by theadditional process steps of adding one or two outer substrates, to formthe laminate 500-a of FIG. 5A, the laminate 500-b of FIG. 5B, thelaminate 500-c of FIG. 5C, the laminate 500-d of FIG. 5D, the laminate700-a of FIG. 7A, the laminate 700-b of FIG. 7B, the laminate 700-c ofFIG. 7C, or the laminate 700-d of FIG. 7D.

FIGS. 9-18 illustrate machines for incrementally stretching and joiningsubstrates to form tip bonded formed laminates, as described herein. InFIGS. 9-18, the substrates are films.

FIG. 9 is an assembly diagram illustrating a machine 902 with four solidstate formation rolls, which are a first patterning roll 960, a secondpatterning roll 970, a third patterning roll 980, and a fourthpatterning roll 990, wherein the machine incrementally stretches a firstsubstrate 910 and a second substrate 920 and joins the substratestogether to form a tip bonded formed laminate 900. The first and thirdpatterning rolls 960 and 980 incrementally stretch the first substrate910; the second and fourth patterning rolls 970 and 990 incrementallystretch the second substrate 920. While the first substrate 910 isengaged with the first patterning roll 960 and while the secondsubstrate 920 is engaged with the second patterning roll 970, the firstand second patterning rolls 960 and 970 join together the first andsecond substrates 910 and 920 to form the laminate 900. In FIG. 9, theoverall machine direction for the first substrate 910 is shown on theleft as an arrow pointing to the right and the overall machine directionfor the second substrate 920 is shown on the right as an arrow pointingto the left; however, for each of these substrates, the precise machinedirection at any particular point is defined by the path of thesubstrate as it travels through the machine.

The first patterning roll 960 is a solid state formation roll withdiscrete protrusions that rotates 960-r clockwise around an axis 965oriented in the cross direction. The first patterning roll 960 has aroll face with a cylindrical base and a plurality of rigid, elongated,discrete protrusions 961 attached to the base as radial projections. Theprotrusions 961 are like rows of teeth, and, on the roll 960, aredisposed linearly, in parallel, side-by-side, with adjacent teethseparated by gaps. Each of the protrusions 961 is elongated since it hasan overall length that is greater than its overall width. And, each ofthe protrusions 961 is oriented lengthwise in the machine direction,such that its overall length is parallel with the rotation of the roll960. Each of the protrusions 961 is discrete with an overall length thatdoes not continue all the way around the roll face of the roll 960. Eachof the protrusions 961 has a distal end that forms a tip, which is thepart of the protrusion that is farthest from the axis 965. The secondpatterning roll 970 is also a solid state formation roll with discreteprotrusions 971, and is configured in the same way as the firstpatterning roll 960, except that the roll 970 rotates 970-rcounterclockwise around an axis 975 oriented in the cross direction.

The first patterning roll 960 is positioned with respect to the secondpatterning roll 970 such that, as the rolls rotate, the tips of theprotrusions 961 are always unmated with the tips of the protrusions 971;that is, when the tips of the protrusions 961 and 971 pass by eachother, the tips of the protrusions 961 are never closer to the axis 975than the tips of the protrusions 971 and the tips of the protrusions 971are never closer to the axis 965 than the tips of the protrusions 961.As a result, there is no intermeshing of the protrusions 961 and 971, asthe rolls 960 and 970 rotate; so, the rolls 960 and 970 are unmated,with respect to each other.

The first patterning roll 960 is also positioned with respect to thesecond patterning roll 970 such that, as the rolls rotate, while thefirst substrate 910 is engaged with the first patterning roll 960 andwhile the second substrate 920 is engaged with the second patterningroll 970, the tips of the protrusions 961 come within joining proximityof the tips of the protrusions 971; that is, when the tips of theprotrusions 961 pass by the tips of the protrusions 971, a substrateengaged with the protrusions 961 can be directly connected to asubstrate engaged with the protrusions 971. As a result, the rolls 960and 970 can join substrates to form a laminate, as they rotate; so, therolls 960 and 970 are joining rolls with respect to each other.

The first patterning roll 960 is registered with the second patterningroll 970 in both the machine direction and the cross direction, toenable the connection of the substrates 910 and 920. The registration inthe machine direction includes controlling the relative angularpositions of the rolls 960 and 970, such that, as the rolls 960 and 970rotate, the tips of the protrusions 961 and 971 pass by each other injoining proximity, so the opposing tips of the protrusions can positioncorrugations from the first substrate 910 with corrugations from thesecond substrate 920 along their overall lengths, to form directconnections, as described and illustrated in connection with FIG. 12B.The registration in the cross direction includes positioning the rollfaces of the rolls 960 and 970, such that, as the rolls 960 and 970rotate, when the tips of the protrusions 961 are in joining proximitywith the tips of the protrusions 971, the tips are aligned in the crossdirection opposite from each other, so the opposing tips can positioncorrugations from the first substrate 910 with corrugations from thesecond substrate 920 across their widths, to form direct connections, asdescribed and illustrated in connection with FIG. 12A.

The third patterning roll 980 is a ring-roll that rotates 980-rcounterclockwise around an axis 985 oriented in the cross direction. Thethird patterning roll 980 has a roll face with a cylindrical base and aplurality of rigid, elongated, continuous protrusions 981 attached tothe base as radial projections. The protrusions 981 are like rows ofrings, and are disposed linearly, in parallel, side-by-side, withadjacent rings separated by gaps. Each of the rings 981 is elongatedsince it has an overall length that is greater than its overall width.And, each of the protrusions 981 is oriented lengthwise in the machinedirection, such that its overall length is parallel with the rotation ofthe roll 980. Each of the protrusions 981 is continuous with an overalllength that continues all the way around the roll face of the roll 980.Each of the protrusions 981 has a distal outer surface that forms a tip,which is the part of the protrusion that is farthest from the axis 995.The fourth patterning roll 990 is also a ring-roll with protrusions 991,and is configured in the same way as the third patterning roll 980,except that the roll 990 rotates 980-r clockwise around an axis 995oriented in the cross direction.

The third patterning roll 980 is positioned with respect to the firstpatterning roll 960 such that, as the rolls rotate, the tips of thecontinuous protrusions 981 mate with the tips of the discreteprotrusions 961; that is, the tips of the protrusions 961 pass withinthe radius formed by the tips of the protrusions 981 and the tips of theprotrusions 981 pass within the radius formed by the tips of theprotrusions 961. As a result, there is an intermeshing of theprotrusions 961 and 981 as the rolls 960 and 980 rotate; so, the rolls960 and 980 are mated, with respect to each other.

The third patterning roll 980 is registered with the first patterningroll 960 in the cross direction, to enable the incremental stretching ofthe substrate 910. The registration in the cross direction includespositioning the roll faces of the rolls 960 and 980, such that, as therolls 960 and 980 rotate, the tips of the continuous protrusions 981 areoffset in the cross direction from the tips of the discrete protrusions961, so the tips can intermesh to form incrementally stretchedcorrugations in the first substrate 910, as described and illustrated inconnection with FIG. 10A. Since the protrusions 981 are continuous,there is no need to register the third patterning roll 980 with thefirst patterning roll 960 in the machine direction.

The fourth patterning roll 990 is positioned and registered with thesecond patterning roll 970 in the same way that the third patterningroll 980 is positioned and registered with the first patterning roll960, such that, the rolls 990 and 970 are mated, with respect to eachother, and the tips of the continuous protrusions 991 intermesh with thetips of the discrete protrusions 971, to form incrementally stretchedcorrugations in the second substrate 920, as described and illustratedin connection with FIG. 10B. Since the protrusions 991 are continuous,there is no need to register the fourth patterning roll 990 with thesecond patterning roll 970 in the machine direction.

The machine 902 also includes several additional apparatuses. A firstweb supply apparatus 950-1 is positioned upstream from the thirdpatterning roll 980, and supplies the first substrate 910 in the form ofa web; a web supply apparatus can take any convenient form, such as anunwind stand. Similarly, a second web supply apparatus 950-2 ispositioned upstream from the fourth patterning roll 990, and suppliesthe second substrate 920 in the form of a web. An adhesive applicationapparatus 952 is positioned adjacent to the first patterning roll 960and applies adhesive to a substrate engaged with the protrusions 961 ofthe roll 960; an adhesive application apparatus can take any convenientform, such as a glue head with a comb shim, a gravure print roll, aninkjet printer, etc. A force application apparatus 954 includes a firstpart that pushes and holds the third patterning roll 980 into matingrelation with the first patterning roll 960 and a second part thatpushes and holds the fourth patterning roll 990 into mating relationwith the second patterning roll 970; a force application apparatus cantake any convenient form, such as air cylinders that move the rolls'rotating axes.

The first substrate 910 generally moves through the machine 902 fromleft to right, as indicated by its overall machine direction. The firstsubstrate 910 moves 910-m from the first web supply apparatus 950-1 ontothe third patterning roll 980, then between the intermeshing protrusions961 and 981 of the mated rolls 960 and 980, then past the adhesiveapplication apparatus 952, and then into the joining proximity betweenthe protrusions 961 and 971 of the rolls 960 and 970. As the firstsubstrate 910 is supplied by the first web supply apparatus 950-1, thefirst substrate 910 has the form of a substantially flat, unformed,continuous web. The first substrate 910 moves 910-m from the first websupply apparatus 950-1 and follows the roll face of the third patterningroll 980. As the third patterning roll 980 rotates, the first substrate910 moves into and engages with the intermeshing protrusions 981 and 961of the patterning rolls 980 and 960, which incrementally mechanicallystretch the first substrate 910 to form a plurality of corrugations withtroughs and crests, as described and illustrated in connection with FIG.10A. As the patterning rolls 980 and 960 rotate, the first substrate 910moves out of the intermeshing protrusions 961 and 981 and disengagesfrom the protrusions 981 of the third patterning roll 980 but remainsengaged with the protrusions 961 of the first patterning roll 960 andfollows the roll face of the first patterning roll 960. As the firstpatterning roll 960 rotates farther, the first substrate 910 continuesto follow the roll face of the first patterning roll 960, remainingengaged with the protrusions 961, and moving past the adhesiveapplication apparatus 952, which applies adhesive to the troughs of thecorrugations of the first substrate 910, as described and illustrated inconnection with FIGS. 11A and 11C. The adhesive application apparatus952 can be positioned adjacent to the first patterning roll 960 at anyconvenient location downstream from the disengagement of the first andthird rolls 960 and 980 and upstream from the joining proximity of thefirst and second rolls 960 and 970. In alternative embodiments, anotheradhesive application apparatus (in addition to or instead of theadhesive application apparatus 952) can be adjacent to the secondpatterning roll 970 at any convenient location downstream from thedisengagement of the second and fourth rolls 970 and 990 and upstreamfrom the joining proximity of the first and second rolls 960 and 970. Asthe first patterning roll 960 rotates even farther, the first substrate910 continues to follow the roll face of the first patterning roll 960,remaining engaged with the protrusions 961, and moving between thepatterning rolls 960 and 970.

The second substrate 920 generally moves through the machine 902 fromright to left, as indicated by its overall machine direction. The secondsubstrate 920 moves 920-m from the second web supply apparatus 950-2onto the fourth patterning roll 990, then between the intermeshingprotrusions 971 and 991 of the mated rolls 970 and 990, and then intothe joining proximity between the protrusions 971 and 991 of the rolls970 and 990. As the second substrate 920 is supplied by the second websupply apparatus 950-2, the second substrate 920 has the form of asubstantially flat, unformed, continuous web. The second substrate 920moves 920-m from the second web supply apparatus 950-2 and follows theroll face of the fourth patterning roll 990. As the fourth patterningroll 990 rotates, the second substrate 920 moves into and engages withthe intermeshing protrusions 991 and 971 of the patterning rolls 990 and970, which incrementally mechanically stretch the second substrate 920to form a plurality of corrugations with troughs and crests, asdescribed and illustrated in connection with FIG. 10B. As the patterningrolls 990 and 970 rotate, the second substrate 920 moves out of theintermeshing protrusions 991 and 971 and disengages from the protrusions991 of the fourth patterning roll 990 but remains engaged with theprotrusions 971 of the second patterning roll 970 and follows the rollface of the second patterning roll 970. As the second patterning roll970 rotates farther, the second substrate 920 continues to follow theroll face of the second patterning roll 970, remaining engaged with theprotrusions 971, as described and illustrated in connection with FIG.11B. As the second patterning roll 970 rotates even farther, the secondsubstrate 920 continues to follow the roll face of the second patterningroll 970, remaining engaged with the protrusions 971, and moving betweenthe patterning rolls 970 and 960.

As the first patterning roll 960 and the second patterning roll 970rotate farther, the first substrate 910 is engaged with the firstpatterning roll 960, the second substrate 920 is engaged with the secondpatterning roll 970, and the tips 962 of the protrusions 961 of thefirst patterning roll 960 come into joining proximity with the tips 972of the protrusions 971 of the second patterning roll 970, such that thetroughs 912 of the corrugations 911 from the first substrate 910 becomeconnected by the adhesive to the troughs 922 of the corrugations 921from the second substrate 920, to form the tip bonded formed laminate900, which moves 900-m off of the rolls 960 and 970 in its finishedform.

In various modified embodiments, one or more additional intermediatesubstrates (e.g. films), can be fed in between a first substrate and asecond substrate at the joining proximity, such that the firstsubstrate, the intermediate substrate(s), and the second substrate canall be joined together by the first patterning roll and the secondpatterning roll, with the intermediate substrate(s) disposed in between,according to embodiments disclosed herein; this approach can be used tomodify any embodiments of process and equipment disclosed in FIGS. 8-17,including any alternative embodiments.

FIG. 10A illustrates an enlarged partial cross-section view of a portion1003-a of the machine 902 of FIG. 9, showing the protrusions 961 of thefirst patterning roll 960 intermeshing with the protrusions 981 of thethird patterning roll 980 to incrementally stretch the first substrate910, and form a plurality of corrugations 911. On the left and rightsides of the portion 1003-a where there are no protrusions of the firstpatterning roll 960 intermeshing with the protrusions 981 of the thirdpatterning roll 980, uncorrugated portions of the first substrate 910lie on top of the protrusions 981, at about the same height as thecrests of the corrugations 911.

FIG. 10B illustrates an enlarged partial cross-section view of a portion1003-b of the machine 902 of FIG. 9, showing the protrusions 971 of thesecond patterning roll 970 intermeshing with the protrusions 991 of thefourth patterning roll 990 to incrementally stretch the second substrate920, and form a plurality of corrugations 921. On the left and rightsides of the portion 1003-b where there are no protrusions of the secondpatterning roll 970 intermeshing with the protrusions 991 of the fourthpatterning roll 990, uncorrugated portions of the second substrate 920lie on top of the protrusions 991, at about the same height as thecrests of the corrugations 921.

FIG. 11A illustrates an enlarged partial cross-sectional view of aportion 1103-a of the machine 902 of FIG. 9, at a location downstreamfrom the portion 1003-a of FIG. 10A, showing the corrugations 911 of thefirst substrate 910 engaged with the protrusions 961 of the firstpatterning roll 960, wherein the troughs 912 of the corrugations 911 aredisposed on tips 962 of the protrusions 961 and an adhesive 931 isselectively applied to the troughs 912. In FIG. 11A, the uncorrugatedportions of the first substrate 910 are in the same positions as in FIG.10A.

FIG. 11B illustrates an enlarged partial cross-sectional view of aportion 1103-b of the machine 902 of FIG. 9, at a location downstreamfrom the portion 1003-b of FIG. 10B, showing the corrugations 921 of thesecond substrate 920 engaged with the protrusions 971 of the secondpatterning roll 970, wherein the troughs 922 of the corrugations 921 aredisposed on tips 972 of the protrusions 971. In FIG. 11B, theuncorrugated portions of the second substrate 920 are in the samepositions as in FIG. 10B.

FIG. 11C illustrates a partial outside view of the first substrate 910(shown in broken part) of FIG. 11A engaged with the first patterningroll 960 (not shown), showing the troughs 912 of the corrugations 911disposed on the tips 962 (shown as hidden) of the protrusions 961 andthe adhesive 931 selectively applied to the troughs 912.

FIG. 12A illustrates an enlarged partial cross-sectional view (in themachine direction) of a portion 1203-a of the machine 902 of FIG. 9, ata location downstream from the portions 1103-a of FIGS. 11A and 1103-bof FIG. 11B, wherein the first substrate 910 is engaged with the firstpatterning roll 960, the second substrate 920 is engaged with the secondpatterning roll 970, and the protrusions 961 of the first patterningroll 960 are in joining proximity with the protrusions 971 of the secondpatterning roll 970, such that the troughs 912 of the corrugations 911from the first substrate 910 are being adhesively connected to thetroughs 922 of the corrugations 921 from the second substrate 920 at aplurality of attachment areas 930, to form the tip bonded formedlaminate 900 of FIG. 9.

FIG. 12B illustrates an enlarged partial cross-sectional view (in thecross direction) of the portion 1203-a of FIG. 12A, wherein the firstsubstrate 910 is engaged with the first patterning roll 960, the secondsubstrate 920 is engaged with the second patterning roll 970, and thetip 962 of one of the protrusions 961 of the first patterning roll 960is in joining proximity with the tip 972 of one of the protrusions 971of the second patterning roll 970, such that one of the troughs 912 ofthe corrugations 911 from the first substrate 910 is being connected byan adhesive 931-1 and 931-2 to one of the troughs 922 of thecorrugations 921 from the second substrate 920 at an attachment area930, to form the tip bonded formed laminate 900 of FIG. 9. A firstportion of the adhesive 931-1 is an upstream portion of the adhesive andis disposed on the first substrate 910 but not yet in contact with thesecond substrate 920. A second portion of the adhesive 931-2 is adownstream portion of the adhesive and is contact with both the firstsubstrate 910 and the second substrate 920.

FIG. 12C illustrates a further enlarged portion of the view from FIG.12B, wherein the first substrate 910 is engaged with the firstpatterning roll 960, the second substrate 920 is engaged with the secondpatterning roll 970, and the tip 962 of one of the protrusions 961 ofthe first patterning roll 960 is in joining proximity 900-jp with thetip 972 of one of the protrusions 971 of the second patterning roll 970.Upstream from the joining proximity 900-jp, the first substrate 910 isseparate from the second substrate 920, and a first portion of theadhesive 931-1 is disposed on an outer portion of a trough 912 of acorrugation 911 of the first substrate 910. At the joining proximity900-jp, the tips 962 and 972 pass by each other, and the adhesive comesinto contact with an outer portion of a trough 922 of a corrugation 921of the second substrate 920. Downstream from the joining proximity900-jp, a second portion of the adhesive 931-2 connects the trough 912of the first substrate 910 to the trough 922 of the second substrate920, such that the adhesively connected substrates 910 and 920 form thetip bonded formed laminate 900 of FIG. 9.

FIG. 13 is an assembly diagram illustrating a machine 1302 with foursolid state formation rolls, which are a first patterning roll 1360, asecond patterning roll 1370, a third patterning roll 1380, and a fourthpatterning roll 1390, wherein the machine incrementally stretches afirst substrate 1310 and a second substrate 1320 and joins thesubstrates 1310 and 1320 together to form a tip bonded formed laminate1300. The first and third patterning rolls 1360 and 1380 incrementallystretch the first substrate 1310; the second and fourth patterning rolls1370 and 1390 incrementally stretch the second substrate 1320. While thefirst substrate 1310 is engaged with the first patterning roll 1360 andwhile the second substrate 1320 is engaged with the second patterningroll 1370, the first and second patterning rolls 1360 and 1370 jointogether the first and second substrates 1310 and 1320 to form thelaminate 1300. In FIG. 13, the overall machine direction for the firstsubstrate 1310 is shown on the left as an arrow pointing to the rightand the overall machine direction for the second substrate 1320 is shownon the right as an arrow pointing to the left; however, for each ofthese substrates, the precise machine direction at any particular pointis defined by the path of the substrate as it travels through themachine.

The machine 1302 of FIG. 13 is configured in the same way as the machine902 of FIG. 9, with like-numbered elements configured in the same way,except as described differently below. On the first patterning roll1360, each of the protrusions 1361 is oriented lengthwise in the crossdirection, such that its overall length is parallel with the axis 1365.Each of the protrusions 1361 is discrete with an overall length thatdoes not extend all the way across the roll face of the roll 1360. Thesecond patterning roll 1370 includes protrusions 1371, and is configuredin the same way as the first patterning roll 1360, except that the roll1370 rotates 1370-r counterclockwise around an axis 1375. The rolls 1360and 1370 are unmated joining rolls, with respect to each other, and areregistered with each other in both the machine direction and the crossdirection, to enable the connection of the substrates 1310 and 1320.

On the third patterning roll 1380, each of the protrusions is orientedlengthwise in the cross direction, such that its overall length isparallel with the axis 1385. Each of the protrusions 1381 is continuouswith an overall length that extends all the way across the roll face ofthe roll 1380. The third patterning roll 1380 is mated to the firstpatterning roll 1360, and the third patterning roll 1380 is registeredto the first patterning roll 1360 in both the machine direction and thecross direction, to enable the incremental stretching of the firstsubstrate 1310.

The fourth patterning roll 1390 includes protrusions 1391, and isconfigured in the same way as the third patterning roll 1380, exceptthat the roll 1390 rotates 1380-r clockwise around an axis 1385. Thefourth patterning roll 1390 is mated to the second patterning roll 1370,and the fourth patterning roll 1390 is registered to the secondpatterning roll 1370 in both the machine direction and the crossdirection, to enable the incremental stretching of the second substrate1320.

In various embodiments, the machine 1302 of FIG. 13 can be configuredaccording to any alternative machine embodiments disclosed herein, inany workable combination.

FIG. 14 is an assembly diagram illustrating a machine 1402 with foursolid state formation rolls, which are a first patterning roll 1460, asecond patterning roll 1470, a third patterning roll 1480, and a fourthpatterning roll 1490, wherein the machine incrementally stretches afirst substrate 1410 and a second substrate 1420 and joins thesubstrates together to form a tip bonded formed laminate 1400. The firstand third patterning rolls 1460 and 1480 incrementally stretch the firstsubstrate 1410; the second and fourth patterning rolls 1470 and 1490incrementally stretch the second substrate 1420. While the firstsubstrate 1410 is engaged with the first patterning roll 1460 and whilethe second substrate 1420 is engaged with the second patterning roll1470, the first and second patterning rolls 1460 and 1470 join togetherthe first and second substrates 1410 and 1420 to form the laminate 1400.In FIG. 14, the overall machine direction for the first substrate 1410is shown on the left as an arrow pointing to the right and the overallmachine direction for the second substrate 1420 is shown on the right asan arrow pointing to the left; however, for each of these substrates,the precise machine direction at any particular point is defined by thepath of the substrate as it travels through the machine.

The machine 1420 of FIG. 14 is configured in the same way as the machine902 of FIG. 9, with like-numbered elements configured in the same way,except as described differently below. The first patterning roll 1460 isa ring-roll with continuous protrusions 1461. The second patterning roll1470 is also a ring-roll with continuous protrusions 1471. The rolls1460 and 1470 are unmated joining rolls, with respect to each other, andare registered with each other in the cross direction, to enable theconnection of the substrates 1410 and 1420. Since the protrusions 1461and 1471 are continuous, there is no need to register the firstpatterning roll 1460 with the second patterning roll 1470 in the machinedirection.

The third patterning roll 1480 is a solid state formation roll withdiscrete protrusions 1481. The third patterning roll 1480 is mated tothe first patterning roll 1460, and the third patterning roll 1480 isregistered to the first patterning roll 1460 in the cross direction, toenable the incremental stretching of the first substrate 1410. Since theprotrusions 1461 are continuous, there is no need to register the thirdpatterning roll 1480 with the first patterning roll 1460 in the machinedirection. The fourth patterning roll 1490 is also a solid stateformation roll with discrete protrusions 1491. The fourth patterningroll 1490 is mated to the second patterning roll 1470, and the fourthpatterning roll 1490 is registered to the second patterning roll 1470 inthe cross direction, to enable the incremental stretching of the secondsubstrate 1420. Since the protrusions 1471 are continuous, there is noneed to register the fourth patterning roll 1490 with the secondpatterning roll 1470 in the machine direction.

In various embodiments, the machine 1402 of FIG. 14 can be configuredaccording to any alternative machine embodiments disclosed herein, inany workable combination.

FIG. 15A illustrates an enlarged partial cross-section view of a portion1503-a of the machine 1402 of FIG. 14, showing the protrusions 1461 ofthe first patterning roll 1460 intermeshing with the protrusions 1481 ofthe third patterning roll 1480 to incrementally stretch the firstsubstrate 1410, and form a plurality of corrugations 1411. On the leftand right sides of the portion 1503-a where there are no protrusions ofthe third patterning roll 1480 intermeshing with the protrusions 1461 ofthe first patterning roll 1460, uncorrugated portions of the firstsubstrate 1410 lie on top of the protrusions 1461, at about the sameheight as the troughs of the corrugations 1411.

FIG. 15B illustrates an enlarged partial cross-section view of a portion1503-b of the machine 1402 of FIG. 14, showing the protrusions 1471 ofthe second patterning roll 1470 intermeshing with the protrusions 1491of the fourth patterning roll 1490 to incrementally stretch the secondsubstrate 1420, and form a plurality of corrugations 1421. On the leftand right sides of the portion 1503-b where there are no protrusions ofthe fourth patterning roll 1490 intermeshing with the protrusions 1471of the second patterning roll 1470, uncorrugated portions of the secondsubstrate 1420 lie on top of the protrusions 1471, at about the sameheight as the troughs of the corrugations 1421.

FIG. 16A illustrates an enlarged partial cross-sectional view of aportion 1603-a of the machine 1402 of FIG. 14, at a location downstreamfrom the portion 1503-a of FIG. 15A, showing the corrugations 1411 ofthe first substrate 1410 engaged with the protrusions 1461 of the firstpatterning roll 1460, wherein the troughs 1412 of the corrugations 1411are disposed on tips 1462 of the protrusions 1461 and an adhesive 1431is selectively applied to the troughs 1412. In FIG. 16A, theuncorrugated portions of the first substrate 1410 are in the samepositions as in FIG. 15A, and the uncorrugated portions of the firstsubstrate 1410 also receive the adhesive 1431 selectively applied acrosstheir widths at locations opposite the tips 1462 of the protrusions1461.

FIG. 16B illustrates an enlarged partial cross-sectional view of aportion 1603-b of the machine 1402 of FIG. 14, at a location downstreamfrom the portion 1503-b of FIG. 15B, showing the corrugations 1421 ofthe second substrate 1420 engaged with the protrusions 1471 of thesecond patterning roll 1470, wherein the troughs 1422 of thecorrugations 1421 are disposed on tips 1472 of the protrusions 1471. InFIG. 16B, the uncorrugated portions of the second substrate 1420 are inthe same positions as in FIG. 16B.

FIG. 17 illustrates an enlarged partial cross-sectional view (in themachine direction) of a portion 1703 of the machine 1402 of FIG. 14, ata location downstream from the portions 1603-a of FIGS. 16A and 1603-bof FIG. 16B, wherein the first substrate 1410 is engaged with the firstpatterning roll 1460, the second substrate 1420 is engaged with thesecond patterning roll 1470, and the protrusions 1461 of the firstpatterning roll 1460 are in joining proximity with the protrusions 1471of the second patterning roll 1470, such that the troughs 1412 of thecorrugations 1411 from the first substrate 1410 are being adhesivelyconnected to the troughs 1422 of the corrugations 1421 from the secondsubstrate 1420 at a plurality of attachment areas 1430, and theuncorrugated portions of the first substrate 1410 are being adhesivelyconnected to the uncorrugated portions of the second substrate 1420, toform the tip bonded formed laminate 1400 of FIG. 14.

FIG. 18 is an assembly diagram illustrating a machine 1802 with foursolid state formation rolls, which are a first patterning roll 1860, asecond patterning roll 1870, a third patterning roll 1880, and a fourthpatterning roll 1890, wherein the machine incrementally stretches afirst substrate 1810 and a second substrate 1820 and joins thesubstrates 1810 and 1820 together to form a tip bonded formed laminate1800. The first and third patterning rolls 1860 and 1880 incrementallystretch the first substrate 1810; the second and fourth patterning rolls1870 and 1890 incrementally stretch the second substrate 1820. While thefirst substrate 1810 is engaged with the first patterning roll 1860 andwhile the second substrate 1820 is engaged with the second patterningroll 1870, the first and second patterning rolls 1860 and 1870 jointogether the first and second substrates 1810 and 1820 to form thelaminate 1800. In FIG. 18, the overall machine direction for the firstsubstrate 1810 is shown on the left as an arrow pointing to the rightand the overall machine direction for the second substrate 1820 is shownon the right as an arrow pointing to the left; however, for each ofthese substrates, the precise machine direction at any particular pointis defined by the path of the substrate as it travels through themachine.

The machine 1802 of FIG. 18 is configured in the same way as the machine1402 of FIG. 14, with like-numbered elements configured in the same way,except as described differently below. On the first patterning roll1860, each of the protrusions 1861 is oriented lengthwise in the crossdirection, such that its overall length is parallel with the axis 1865.Each of the protrusions 1861 is continuous with an overall length thatextends all the way across the roll face of the roll 1860. The secondpatterning roll 1870 includes protrusions 1871, and is configured in thesame way as the first patterning roll 1860, except that the roll 1870rotates 1870-r counterclockwise around an axis 1875. The rolls 1860 and1870 are unmated joining rolls, with respect to each other, and areregistered with each other in both the machine direction and the crossdirection, to enable the connection of the substrates 1810 and 1820.

On the third patterning roll 1880, each of the protrusions is orientedlengthwise in the cross direction, such that its overall length isparallel with the axis 1885. Each of the protrusions 1881 is discretewith an overall length that does not extend all the way across the rollface of the roll 1880. The third patterning roll 1880 is mated to thefirst patterning roll 1860, and the third patterning roll 1880 isregistered to the first patterning roll 1860 in both the machinedirection and the cross direction, to enable the incremental stretchingof the first substrate 1810.

The fourth patterning roll 1890 includes protrusions 1891, and isconfigured in the same way as the third patterning roll 1880, exceptthat the roll 1890 rotates 1890-r clockwise around an axis 1895. Thefourth patterning roll 1890 is mated to the second patterning roll 1870,and the fourth patterning roll 1890 is registered to the secondpatterning roll 1870 in both the machine direction and the crossdirection, to enable the incremental stretching of the second substrate1820.

In various embodiments, the machine 1802 of FIG. 18 can be configuredaccording to any alternative machine embodiments disclosed herein, inany workable combination.

Although the machine embodiments disclosed herein describe andillustrate solid state formation elements as rotating patterning rolls,in various embodiments, any such rolls may be replaced by one or moreother kinds of solid state formation elements, such as planar patterningsurfaces having similar protrusions, but which move into matingrelationship and/or joining proximity with non-rotating movement (e.g.linear motion), as will be understood by one skilled in the art of solidstate formation.

FIG. 19 is an enlarged cross-sectional view of a portion of a laminate1900 with a patterned area formed by a first substrate 1910 and a secondsubstrate 1920 along with a first outer substrate 1940-1 and a secondouter substrate 1940-2 wherein the laminate includes benefit agentsdisposed at locations within the laminate 1900. The portion of thelaminate 1900 is configured in the same way as a corresponding portionfrom the laminate 500-a of FIG. 5A and is also configured in the sameway as a corresponding portion from the laminate 700-a of FIG. 7A, withlike-numbered elements in configured in the same way, except asdescribed below.

The troughs 1912 of the corrugations 1911 from the first substrate 1910are connected by an adhesive 1931 to the troughs 1922 of thecorrugations 1921 from the second substrate 1920 at attachment areas1930, and the adhesive 1931 includes one or more benefit agents, whichcan be any benefit agent disclosed herein or known in the art; for anylaminate disclosed herein, any adhesive that connects the troughs ofcorrugations of first and second substrates, can include a benefitagent, which can be mixed into the adhesive and thus disposed on thelaminate as part of the adhesive application process.

The inner portions of the crests 1913 of the corrugations 1911 from thefirst substrate 1910 include a benefit agent 1909-1 disposed on theirsurfaces, and the inner portions of the crests 1923 of the corrugations1921 from the second substrate 1920 include a benefit agent 1909-2disposed on their surfaces; the benefit agents 1909-1 and 1909-2 can beone or more of any benefit agent disclosed herein or known in the art,and may be applied directly or indirectly to the surfaces, in anyconvenient way (e.g. by spraying on) disclosed herein or known in theart.

The outer portions of the crests 1913 of the corrugations 1911 from thefirst substrate 1910 are connected by an adhesive 1932-1 at a pluralityof locations to an inner side of the first outer substrate 1940-1 andthe outer portions of the crests 1923 of the corrugations 1921 from thesecond substrate 1920 are connected by an adhesive 1932-2 at a pluralityof locations to an inner side of the second outer substrate 1940-2,wherein the adhesive 1932-1 and the adhesive 1932-2 each include one ormore benefit agents, which can be any benefit agent disclosed herein orknown in the art; for any laminate disclosed herein having an outersubstrate, any adhesive that connects the crests of corrugations of asubstrate to an outer substrate, can include a benefit agent, which canbe mixed into the adhesive and thus disposed on the laminate as part ofthe adhesive application process.

In various alternative, embodiments, the presence of some or all of thebenefit agents disposed in the portion of the laminate 1900 may beomitted; the presence or absence of benefit agents may be repeatedacross part, parts, or all of a laminate.

FIG. 20A is an enlarged end view of a portion of an exemplary laminate2010-a of the present disclosure, which illustrates the extent of acrest 2013 in a corrugation of a substrate of the laminate 2010-a. Thecrest 2013 is an outward facing portion of the wave-like corrugationwith a convex shaped surface that is oriented outward, away from theinterior of the laminate and its central plane 2007-a. The crest 2013refers to the continuous section of that outward facing portion whereinreference lines (shown as phantom lines) drawn perpendicular to thesubstrate form inside angles of 45-90 degrees, with respect to thecentral plane 2007-a of the laminate 2010-a.

FIG. 20B is an enlarged end view of a portion of an exemplary laminate2010-b of the present disclosure, which illustrates the extent of atrough 2012 in a corrugation of a substrate of the laminate 2010-b. Thetrough 2012 is an inward facing portion of the wave-like corrugationwith a convex shaped surface that is oriented inward, toward theinterior of the laminate and its central plane 2007-b. The trough 2012refers to the continuous section of that inward facing portion whereinreference lines (shown as phantom lines) drawn perpendicular to thesubstrate form inside angles of 45-90 degrees, with respect to thecentral plane 2007-b of the laminate 2010-b.

FIG. 21 is an enlarged end view of a portion of an exemplary laminate2100 of the present disclosure formed by a first substrate 2110 and asecond substrate 2120. The portion of the laminate 2100 is configured inthe same way as a corresponding portion from the laminate 400-a of FIG.4A and is also configured in the same way as a corresponding portionfrom the laminate 600-a of FIG. 6A, with like-numbered elements inconfigured in the same way, unless otherwise described below. FIG. 21 isintended to illustrate measurements for wavelength and amplitude, forall embodiments of laminates described herein. The laminate 2100includes a central plane 2107, for reference, which is disposedthroughout the middle of the laminate 2100; since the first substrate2110 and the second substrate 2120 are symmetrical in the laminate 2100,the central plane 2107 is disposed between the troughs of thesubstrates.

The first substrate 2110 includes a first inward facing trough 2112-a,and a first outward facing crest 2113-a, which is the crest that isadjacent to the first trough 2112-a; the first trough 2112-a and thefirst crest 2113-a are integrally connected to opposite ends of a firstintermediate portion 2118-a, which is the substantially straight portionof the first substrate 2110 in between the first trough 2112-a and thefirst crest 2113-a. The first trough 2112-a includes a smallestthickness 2112-a-ot, which is measured linearly, perpendicular to thefirst substrate 2110, at a location on the first trough 2112-a wherethat measurement is the smallest; a smallest thickness of a trough mayusually be found at or near its farthest extent, proximate to anadjacent intermediate portion, although this is not required. The firstcrest 2113-a includes a smallest thickness 2113-a-ot, which is measuredlinearly perpendicular to the first substrate 2110, at a location on thefirst crest 2113-a where that measurement is the smallest; a smallestthickness of a crest may usually be found at or near its farthestextent, proximate to an adjacent intermediate portion, although this isnot required. The first intermediate portion 2118-a includes a firstintermediate smallest thickness 2118-a-ot, which is measured linearly,perpendicular to the first substrate 2110, at a location on the firstintermediate portion where that measurement is the smallest; a smallestthickness of an intermediate portion may usually be found at or near itsmiddle, although this is not required. The first intermediate smallestthickness 2118-a-ot is less than the first trough smallest thickness2112-a-ot and the first intermediate smallest thickness 2118-a-ot isalso less than the first crest smallest thickness 2113-a-ot; thesedifferential relationships in thickness result from localized variablethinning of the first substrate 2110 during its incremental stretching,wherein the first substrate 2110 thins out the most in the firstintermediate portion, which is the least constrained portion of thesubstrate material as it is stretched. The relationships and thicknessesof the first trough 2112-a, the first intermediate portion 2118-a, andthe first crest 2113-a are repeated for the same adjacent elements inthe first substrate 2110 and are also present for corresponding adjacentelements in the second substrate 2120.

The first substrate 2110 includes a second crest 2113-b, which is thecrest that is adjacent to the first crest 2113-a. The overall distancebetween the center of the first crest 2113-a and the center of thesecond crest 2113-b is wavelength 2114, which is measured linearly,parallel to the central plane 2107 of the laminate 2100, andperpendicular to the overall orientations of the crests used for themeasurement, as described and illustrated in connection with FIG. 21; awavelength between any adjacent crests can be measured in this way forany laminate disclosed herein. The overall height of the second crest2113-b is amplitude 2115, which is measured linearly from andperpendicular to the central plane 2107 of the laminate 2100 to an outerportion of the second crest 2113-b that is farthest away from the 2107central plane; an amplitude of any crest can be measured in this way forany laminate disclosed herein.

The troughs 2112-a, 2112-b, and 2112-c of the first substrate 2110 areattached to the troughs 2122 of the second substrate 2120 by a pluralityof attachment areas 2105, each of which has an overall width 2105-ow,which is the overall distance between farthest apart portions of theattachment area, measured linearly, parallel to the central plane 2107of the laminate 2100, and perpendicular to the overall orientations ofthe troughs being attached by the attachment area; an overall width ofany attachment area can be measured in this way for any laminatedisclosed herein.

FIG. 22 is an exemplary drawstring type trash bag 2200, made of one ormore films, the bag 2200 having a top 2200-t, a bottom 2200-b, and sides2200-s. The bottom 2200-b is closed with a fold 2200-f, the sides aresealed with side seals 2200-ss, and the top 2200-t includes an opening2200-o. At the top 2200-t, the bag 2200 includes a draw tape 2200-dtdisposed within a hem 2200-h of folded bag material sealed to itself. Afold zone 2200-fz in a bottom portion of the bag 2200 includes the fold2200-f and a portion of the bag 2200 adjacent to the fold 2200-f. A hemzone 2200-hz in a top portion of the bag 2200 includes the hem 2200-hand a portion of the bag 2200 adjacent to the hem 2200-h. A body zone2200-bz of the bag 2200 extends all across the bag, between the top ofthe fold zone 2200-fz and the bottom of the hem zone 2200-hz.

Part, parts, or all of the bag 2200 and its draw tape 2200-dt can beconfigured to be formed of tip-bonded laminates according to one or moreof any of the embodiments of the present disclosure, which may also beconfigured with one or more of any of the patterned areas of the presentdisclosure, in any workable combination, disclosed herein or known inthe art. In particular, part, parts, or all of the top 2200-t, part,parts, or all of the bottom 2200-b, part, parts, or all of either orboth sides 2200-s, part, parts, or all of the fold 2200-f, part, parts,or all of the fold zone 2200-fz, part, parts, or all of the draw tape2200-dt, part, parts, or all of the hem 2200-h, part, parts, or all ofthe hem zone 2200-hz, and/or part, parts, or all of the body zone2200-bz, individually, or in any combination, can be configured as atip-bonded laminate, which may include one or more patterned areasformed from a tip-bonded laminate.

The drawstring type trash bag 2200 can be made from any kind of one ormore films including materials disclosed herein or known in the art; thebag 2200 can be made using any process and equipment for makingdrawstring type trash bags, known in the art; the bag 2200 can befurther configured and/or modified according any embodiments known inthe art of disposable bags.

FIG. 23 is an exemplary tie type trash bag 2300, made of one or morefilms, the bag 2300 having a top 2300-t, a bottom 2300-b, and sides2300-s. The bottom 2300-b is closed with a fold 2300-f, the sides aresealed with side seals 2300-ss, and the top 2300-t includes an opening2300-o. At the top 2300-t, the bag 2300 includes tie flaps 2300-tf (onthe front, shown folded down; on the back, shown upright) disposed asshaped integral parts of the bag material. A fold zone 2300-fz in abottom portion of the bag 2300 includes the fold 2300-f and a portion ofthe bag 2300 adjacent to the fold 2300-f. A flap zone 2300-fz in a topportion of the bag 2300 includes the tie flaps 2300-tf and a portion ofthe bag 2300 adjacent to the tie flaps 2300-tf. A body zone 2300-bz ofthe bag 2300 extends all across the bag, between the top of the foldzone 2300-fz and the bottom of the flap zone 2300-fz. Part, parts, orall of the bag 2300 can be configured to be formed of tip-bondedlaminates according to one or more of any of the embodiments of thepresent disclosure, which may also be configured with one or more of anyof the patterned areas of the present disclosure, in any workablecombination, disclosed herein or known in the art. In particular, part,parts, or all of the top 2300-t, part, parts, or all of the bottom2300-b, part, parts, or all of either or both sides 2300-s, part, parts,or all of the fold 2300-f, part, parts, or all of the fold zone 2300-fz,part, parts, or all of one, or some, or all of the tie flaps 2300-tf,part, parts, or all of the flap zone 2300-fz, and/or part, parts, or allof the body zone 2300-bz, individually, or in any combination, can beconfigured as a tip-bonded laminate, which may include one or morepatterned areas formed from a tip-bonded laminate.

The tie type trash bag 2300 can be made from any kind of film includingmaterials disclosed herein or known in the art; the bag 2300 can be madeusing any process and equipment for making tie type trash bags, known inthe art; the bag 2300 can be further configured and/or modifiedaccording any embodiments known in the art of disposable bags.

In addition to drawstring type and tie type trash bags, tip-bondedlaminates of the present disclosure can be similarly applied to part,parts, or all of film-based materials, components, and/or articles,including: any kind of bag (e.g. other kinds of trash bags, food storagebags, grocery bags, etc.); as a packaging and/or component material forany kind of film used with disposable wearable absorbent articles (e.g.feminine hygiene products, baby diapers, adult incontinence products,sanitary napkins, etc.), bandages, consumer products, other kinds ofproducts, etc.

Tip bonded formed laminates of the present disclosure can be made frommultiple layers of formed substrates, and can offer significantimprovements over unformed, single layer substrates, including: greaterresistance to bending, improved resilience to compression, directionallyoriented responses to tensile loads, better aesthetics, enhancedstructural properties, thicker portions, and designed patterns, withoutrelying on more expensive polymers and/or high concentrations ofsubstrate additives; as a result, such tip bonded formed laminates offersignificant improvements at a reasonable cost, when compared withunformed, single layer substrates.

Test Method to Determine Localized Film Thickness

A Hitachi S-3500N Scanning Election Microscope (Tokyo, Japan) is theimaging device used to quantify the thickness of a film at specificlocations on a 3D substrate.

Sample Preparation

A 2 cm×2 cm square is cut from the article. The 2 cm×2 cm square cut outis placed in 1 liter of liquid nitrogen for 5 minutes. Immediately afterremoving the 2 cm×2 cm square cut out from the liquid nitrogen, a 5 mm×5mm square is cut from within the 2 cm×2 cm square with a new razor bladeto create a cross-sectioned edge. The 5 mm×5 mm specimen has no holes,wrinkles, or gels. Five separate 5 mm×5 mm specimens are created by thesame procedure. The 5 mm×5 mm samples are held for 24 hours at 24°C.+/−3° C. prior to imaging.

The cross-sectioned specimen is removed from liquid nitrogen withtweezers and mounted, cut surface up, onto an aluminum pin mount (e.g.,Ted Pella #16111) using adhesive tabs (e.g., Ted Pella #16084-1). Themounted specimen is sputter-coated with gold to ensure no charging onthe surface during subsequent scanning electron microscopy. Threeminutes of sputter-coating at 45 mA is usually sufficient; if chargingoccurs, however, the specimen should be coated longer.

Imaging

The pin mount containing the coated specimen is fixed to an adapter(e.g., Ted Pella #15387-2) and inserted into the chamber of the HitachiS-3500N SEM. The cross-sectioned surface is imaged under high vacuumwith a voltage of 5 kV and a working distance of 11 mm to amagnification of 800× results in an image that is 2560×1920 pixels (160μm×120 μm), for a resolution of 16 pixels per micron in both X and Y.Images of the directly adjacent crest, span and intermediate portion forcomparison relative to the present invention are captured.

Image Analysis:

The captured image is opened in Quartz PCI 7 Image Software (QuartzImaging Corporation, Vancouver, CAN). Prior to measurement, the softwareis calibrated by drawing a straight line across the length of the scalebar stored in the image and entering in the known length of that bar(e.g., 50 μm). Afterwards, a perpendicular line is drawn across the cutsurface of the imaged specimen, and thickness measurements in thedesired portion are calculated using the software. The imaging procedureis repeated 5 times for each of the prepared 5 mm×5 mm specimens. Thethickness measurements are reported to the nearest 0.1 micron.

Definitions

As used herein, when the term “about” modifies a particular value, theterm refers to a range equal to the particular value, plus or minustwenty percent (+/−20%). For any of the embodiments disclosed herein,any disclosure of a particular value, can, in various alternateembodiments, also be understood as a disclosure of a range equal toabout that particular value (i.e. +/−20%).

As used herein, the term “amplitude” refers to the overall height of acrest in a laminate, wherein the overall height is measured linearlyfrom and perpendicular to a central plane of the laminate to an outerportion of the crest that is farthest away from the central plane, asdescribed and illustrated in connection with FIG. 21.

As used herein, when the term “approximately” modifies a particularvalue, the term refers to a range equal to the particular value, plus orminus fifteen percent (+/−15%). For any of the embodiments disclosedherein, any disclosure of a particular value, can, in various alternateembodiments, also be understood as a disclosure of a range equal toapproximately that particular value (i.e. +/−15%).

As used herein, the term “benefit agent” refers to a chemistry (in solidor liquid form) that is disposed in or on the structure of a material inorder for the chemistry to deliver one or more distinct functions, suchas consumer noticeable effects; examples of benefit agents include:abrasives, absorbents, activators, additives, antibacterials,antifungals, antimicrobials, antioxidants, attractants, bleaches,brighteners, carriers, catalysts, chelators, cleaning agents, colorants,conditioners, desiccants, detergents, diluents, dispersants, dyes,enzymes, exfoliants, fertilizers, flavors or flavonoids, foaming agents,fragrances, herbicides, humectants, inhibiters, minerals, modifiers,moisturizers, moldicides, nutraceuticals, odor absorbent, oils,oxidizers, perfumes, pesticides, pharmaceuticals, phase changematerials, pigments, plasticizers, preservatives, processing aids,purifiers, rinses, scavengers, scrubbers, sensates, sequestrants,shampoos, silicones, softeners, solvents, stabilizers, surfactants,thickeners, treatments, vitamins, waxes, and any other kind of benefitagent known in the art, in any workable combination.

As used herein, the term “crest” refers to a particular outward facingportion of a wave-like corrugation in a substrate of a tip-bonded formedlaminate of the present disclosure, as described below and as furtherdescribed and illustrated in connection with FIG. 20A. The crest isoutward facing in that its convex shaped surface is oriented outward,away from the interior of the laminate. The crest refers to thecontinuous section of that outward facing portion of the corrugationwherein reference lines drawn perpendicular to the substrate form insideangles (illustrated in FIG. 20A) of 45-90 degrees, with respect to acentral plane of the laminate.

As used herein, the term “like-numbered” refers to similar alphanumericlabels for corresponding elements, as described below. Like-numberedelements have labels with the same last two digits; for example, oneelement with a label ending in the digits 20 and another element with alabel ending in the digits 20 are like-numbered. Like-numbered elementscan have labels with differing leading digit(s), wherein that leadingdigit(s) matches the number for its Figure; as an example, an element ofFIG. 3 labeled 320 and an element of FIG. 4 labeled 420 arelike-numbered. Like-numbered elements can have labels with a suffix(i.e. the portion of the label following the dash symbol) that is thesame or possibly different (e.g. corresponding with a particularembodiment); for example, a first embodiment of an element in FIG. 3Alabeled 320-a and a second embodiment of an element in FIG. 3B labeled320-b, are like numbered.

As used herein, when the term “nearly” modifies a particular value, theterm refers to a range equal to the particular value, plus or minus fivepercent (+/−5%). For any of the embodiments disclosed herein, anydisclosure of a particular value, can, in various alternate embodiments,also be understood as a disclosure of a range equal to approximatelythat particular value (i.e. +/−5%). As used herein, the term “overallwidth of an attachment area” refers to the overall distance betweenfarthest apart portions of the attachment area, wherein the overallwidth is measured linearly, parallel to a central plane of the laminateand perpendicular to the overall orientations of the troughs beingattached by the attachment area, as described and illustrated inconnection with FIG. 21. For an attachment area formed by adhering, theoverall width is the measured width of the attaching adhesive. For anattachment area formed by fusing, the overall width is the measuredwidth of the fused portions.

As used herein, the term “solid state formation” refers to a process orequipment in which a mechanical force is exerted upon a substrate (e.g.film), which is in a solid state, wherein the force is applied by one ormore rigid protrusions, which contact and permanently deform portions ofthe substrate by incremental stretching. Examples of solid stateformation equipment include patterning rolls, patterning plates, and/orpatterning belts with discrete and/or continuous rigid protrusions forengaging with and deforming one or more substrates of material, whereinthe protrusions may be of any kind known in the art (e.g. fins, ridges,rings, rods, teeth, etc.), having any convenient size and proportions(e.g. uniform height, variable heights, etc.), and any overall shapeknown in the art (e.g. conical, cuboid, cylindrical, prismatic,pyramidal, etc.), along with any particular tip shape (e.g. flat,pointed, rounded, sharp, etc.), wherein the protrusions extend out froma base over part, parts, or all of the patterning roll/plate/belt. Inparticular, it contemplates that any of the patterning rolls disclosedherein can be replaced by a patterning roll or patterning belt, as knownin the art of solid state formation. Notably, solid state formation of afilm based substrate differs from other substrate formation processessuch as molding (where substrates are shaped while in a semi-molten ormolten state), wet-laid processes (where a wet substrate of fibers isshaped before being dried), and embossing (where a pattern of low-straindeformations is made in a substrate by using a patterning roll to pressthe substrate against a flat or deformable roll).

Any embodiment of substrate made of films, as described herein, can bemade using various solid state formation processes known in the art,including any processes applicable to films, which are disclosed in anyof the following, each of which is incorporated by reference:

As used herein, when the term “substantially” modifies a particularvalue, the term refers to a range equal to the particular value, plus orminus ten percent (+/−10%). For any of the embodiments disclosed herein,any disclosure of a particular value, can, in various alternateembodiments, also be understood as a disclosure of a range equal toapproximately that particular value (i.e. +/−10%). As used herein, theterm “trough” refers to a particular inward facing portion of awave-like corrugation in a substrate of a tip-bonded formed laminate ofthe present disclosure, as described below and as further described andillustrated in connection with FIG. 20B. The trough is inward facing inthat its convex shaped surface is oriented inward, toward the interiorof the laminate. The trough refers to the continuous section of thatinward facing portion of the corrugation wherein reference lines drawnperpendicular to the substrate form inside angles of 45-90 degrees (asillustrated in FIG. 20B), with respect to a central plane of thelaminate.

As used herein, the term “wavelength” refers to the overall distancebetween the centers of adjacent crests in a laminate, wherein thewavelength is measured linearly, parallel to a central plane of thelaminate, and perpendicular to the overall orientations of the crestsused for the measurement as described and illustrated in connection withFIG. 21.

Examples/Combinations—Laminates

A1. A laminate comprising:

a first film having a first plurality of integrally connected,incrementally stretched, elongated corrugations disposed side-by-side,each having:

-   -   a first inward facing trough, which has a first trough smallest        thickness;    -   a first outward facing crest, which has a first crest smallest        thickness; and    -   a first intermediate portion disposed between the first trough        and the first crest, wherein    -   the first intermediate portion has a first intermediate smallest        thickness, which is less    -   than the first crest smallest thickness;

a second film having a second plurality of integrally connected,incrementally stretched, elongated corrugations disposed side-by-side,each having:

-   -   a second inward facing trough, which has a second trough        smallest thickness;    -   a second outward facing crest, which has a second crest smallest        thickness; and    -   a second intermediate portion disposed between the second trough        and the second crest, wherein the second intermediate portion        has a second intermediate thickness,    -   which is less than the second crest smallest thickness;

a plurality of attachment areas, wherein each of the attachment areas isdirectly connected to a trough of a corrugation from the first pluralityto a trough of a corrugation from the second plurality.

A2. The laminate of paragraph A1, wherein the first intermediatesmallest thickness is less than the first trough smallest thickness, andthe second intermediate smallest thickness is less than the secondtrough smallest thickness.A3. The laminate of paragraph A2, wherein each of the corrugations fromthe first plurality is directly connected to only one of thecorrugations from the second plurality.A4. The laminate of paragraph A3, wherein each of the corrugations fromthe second plurality is directly connected to only one of thecorrugations from the first plurality.A5. The laminate of any one of paragraphs A1 to A4, wherein:

the corrugations of the first plurality are discrete corrugations; and

the corrugations of the second plurality are discrete corrugations.

A6. The laminate of any one of paragraphs A1 to A4, wherein:

the corrugations of the first plurality are discrete corrugations; and

the corrugations of the second plurality are continuous corrugations.

A7. The laminate of any one of paragraphs A1 to A4, wherein:

the corrugations of the first plurality are continuous corrugations; and

the corrugations of the second plurality are continuous corrugations.

A8. The laminate of any one of paragraphs A1-A7, wherein the firstplurality is only connected to the second plurality by the plurality ofattachment areas.A9. The laminate of any one of paragraphs A1-A8, wherein each of theattachment areas is substantially continuous along a trough of acorrugation from the first plurality.A10. The laminate of paragraph A9, wherein each of the attachment areasis substantially continuous along a trough of a corrugation from thesecond plurality.A11. The laminate of any one of paragraphs A1 to A10, wherein:

the first plurality connects to a first uncorrugated portion of thefirst film at a first transition;

the second plurality connects to a second uncorrugated portion of thesecond film at a second transition that is offset from the firsttransition.

A12. The laminate of any one of paragraphs A1 to A10, wherein:

the first plurality connects to a first uncorrugated portion of thefirst film at a first transition;

the second plurality connects to a second uncorrugated portion of thesecond film at a second transition that is adjacent to the firsttransition.

A13. The laminate of any one of paragraphs A1-A12, wherein for at leastsome of the corrugations of the first plurality, a ratio of an amplitudeof the corrugation to a wavelength of the corrugation is from 0.7 to 5.A14. The laminate of paragraph A13, wherein for substantially all of thecorrugations of the first plurality, the ratio of the amplitude to thewavelength is from 1 to 3.A15. The laminate of any one of paragraphs A13 or A14, wherein for atleast some of the corrugations of the first plurality, the amplitude isfrom 1 to 10 millimeters.A16. The laminate of paragraph A15, wherein for substantially all of thecorrugations of the first plurality, the amplitude is from 1 to 4millimeters.A17. The laminate of any one of paragraphs A13 to A16, wherein for atleast some of the corrugations of the first plurality, preferably forall of the corrugations, a ratio of the wavelength to an overall widthof an attachment area for the corrugation is from 10 to 50, preferablyfrom 25 to 50.A18. The laminate of paragraph A17, wherein for at least some of thecorrugations of the first plurality, the overall width of the attachmentarea is from 0.2 to 1 millimeters.A19. A disposable wearable absorbent article comprising the laminate ofany one of paragraphs A1-A18.A20. A disposable bag comprising the laminate of any one of paragraphsA1 to A18.

Examples/Combinations—Methods of Forming Laminates

B1. A method of forming a laminate, the method comprising:

incrementally mechanically stretching a first film by engaging at leasta first portion of the first film with at least a first plurality ofprotrusions to form within the first portion a first plurality ofintegrally connected, elongated corrugations disposed side-by-side, eachhaving a trough and a crest;

incrementally mechanically stretching a second film by engaging at leasta second portion of the second film with at least a second plurality ofprotrusions to form within the second portion a second plurality ofintegrally connected, elongated corrugations disposed side-by-side, eachhaving a trough and a crest; and

while the portion of the first film is engaged with the first pluralityof protrusions, and while the portion of the second film is engaged withthe second plurality of protrusions, directly connecting the firstplurality of corrugations to the second plurality of corrugations at aplurality of attachment areas, to form the laminate.

B2. The method of paragraph B1, wherein the stretching of the first filmincludes forming the first plurality of corrugations, which are discretecorrugations.B3. The method of any one of paragraphs B1 or B2, wherein the stretchingof the second film includes forming the second plurality ofcorrugations, which are discrete corrugations.B4. The method of any one of paragraphs B1-B3, wherein the connectingincludes directly connecting the first plurality to the second pluralityat the plurality of attachment areas, such that each trough of acorrugation from the first plurality is directly connected to a singletrough of a corrugation from the second plurality.B5. The method of any one of paragraphs B1-B4, wherein the connectingincludes directly connecting the first plurality to the second pluralityonly at the plurality of attachment areas.B6. The method of any one of paragraphs B1-B5, wherein the connectingincludes directly connecting the first plurality to the second pluralitysuch that each of attachment areas is substantially continuous along atleast one of the troughs.B7. The method of any one of paragraphs B1-B6, wherein the firstplurality of protrusions are parallel with each other, such that thestretching of the first film forms the first plurality of corrugations,which are parallel with each other.B8. The method of paragraph B7, wherein, during the connecting, thefirst plurality of corrugations are parallel with the second pluralityof corrugations.B9. The method of any one of paragraphs B1-B8, including, before theconnecting, registering the first plurality of corrugations with thesecond plurality of corrugations in a cross direction.B10. The method of any one of paragraphs B1-B9, including, before theconnecting, registering the first plurality of corrugations with thesecond plurality of corrugations in a machine direction.B11. The method of any one of paragraphs B1-B10, wherein the connectingincludes adhering the troughs of the corrugations from the firstplurality to the troughs of the corrugations from the second plurality.B12. The method of paragraph B11, including applying adhesive to thefirst film only on troughs of corrugations of the first film.B13. The method of any one of paragraphs B1-B11, wherein the connectingincludes fusing the troughs of the corrugations from the first pluralityto the troughs of the corrugations from the second plurality.B14. The method of any one of paragraphs B1-B13, wherein the stretchingof the first film includes stretching with the first plurality ofprotrusions, which are disposed on a first base adjacent to a portion ofthe first base that is free of protrusions, such that the laminateincludes a first uncorrugated portion adjacent to at least a side of theplurality of attachment areas.B15. The method of paragraph B14, wherein the stretching of the secondfilm includes stretching with the second plurality of protrusions, whichare disposed on a second base adjacent to a portion of the second basethat is free of protrusions, such that the laminate includes a seconduncorrugated portion adjacent to at least the side of the plurality ofattachment areas.B16. The method of any one of paragraphs B14 or B15, wherein the seconduncorrugated portion surrounds the plurality of attachment areas.B17. The method of any one of paragraphs B15 or B16, wherein the seconduncorrugated portion is independent from the first uncorrugated portion.B18. The method of any one of paragraphs B15-B17, wherein the seconduncorrugated portion is offset from the first uncorrugated portion.B19. The method of any one of paragraphs B1-B18, including joining afirst outer film to at least some crests of the corrugations from thefirst plurality.B20. The method of any one of paragraphs B1-B19, including joining asecond outer film to at least some crests of the corrugations from thesecond plurality.

Examples/Combinations—Machines for Forming Laminates

C1. A machine for forming a laminate, the machine comprising:

a machine direction and a cross direction;

a first web supply apparatus and a second web supply apparatus, whichare the only web supply apparatus of the machine;

a first rotating patterning roll, which is downstream from the first websupply apparatus and having a first plurality of rigid, elongatedprotrusions, each with a tip; and

a second rotating patterning roll, which is downstream from the firstweb supply apparatus and having a second plurality of rigid, elongatedprotrusions, each with a tip;

wherein the first roll is positioned with respect to the second rollsuch that, as the rolls rotate:

-   -   the tips of the first plurality are always unmated with the tips        of the second plurality;    -   the tips of the first plurality come within joining proximity of        the tips of the second plurality, wherein the joining proximity        is 0-5 millimeters.        C2. The machine of paragraph C1, wherein: each protrusion of the        first plurality is a discrete protrusion; and each protrusion of        the second plurality is a discrete protrusion.        C3. The machine of paragraph C2, wherein each of the patterning        rolls is a solid state formation roll with discrete protrusions.        C4. The machine of paragraph C1, wherein: each protrusion of the        first plurality is a discrete protrusion; and each protrusion of        the second plurality is a continuous protrusion.        C5. The machine of paragraph C1, wherein: each protrusion of the        first plurality is a continuous protrusion; and each protrusion        of the second plurality is a continuous protrusion.        C6. The machine of paragraph C1, wherein each of the patterning        rolls is a ring-roll.        C7. The machine of any one of paragraphs C2, C4, or C5, wherein:        each protrusion of the first plurality is oriented lengthwise in        the cross direction; and each protrusion of the second plurality        is oriented lengthwise in the cross direction.        C8. The machine of any one of paragraphs C2, C5, or C6, wherein:        each protrusion of the first plurality is oriented lengthwise in        the machine direction; and each protrusion of the second        plurality is oriented lengthwise in the machine direction.        C9. The machine of any one of paragraphs C1-C8, wherein the        first roll is registered with the second roll such that each of        the tips of the first plurality is aligned with one tip from the        second plurality.        C10. The machine of any one of paragraphs C2, C4, or C5,        wherein: each protrusion of the first plurality is oriented        lengthwise in the cross direction; and each protrusion of the        second plurality is oriented lengthwise in the machine        direction.        C11. The machine of any one of paragraphs C2, C4, or C5,        wherein:

each protrusion of the first plurality is oriented lengthwise at a firstangle from 1-89° with respect to the machine direction;

each protrusion of the second plurality is oriented lengthwise at asecond angle between with respect to the machine direction, wherein thesecond angle is about equal to and opposite from the first angle.

C12. The machine of any one of paragraphs C1-C11, wherein the first rollis registered with the second roll such that as the rolls rotate, thefirst plurality at least partially aligns with the second plurality.C13. The machine of any one of paragraphs C1-C12, wherein the first rollis registered with the second roll in the machine direction.C14. The machine of any one of paragraphs C1-C13, including a thirdpatterning roll that is mated with the first patterning roll and isdownstream from the first web supply apparatus.C15. The machine of any one of paragraphs C1-C14, including a fourthpatterning roll that is mated with the second patterning roll and isdownstream from the second web supply apparatus.C16. The machine of any one of paragraphs C1-C15, including a firstadhesive application apparatus that applies adhesive to a film engagedwith the first patterning roll.C17. The machine of any one of paragraphs C1-C16, including a forceapplication apparatus that moves the first roll toward the second roll.C18. The machine of any one of paragraphs C1-C17, wherein the joiningproximity is 0-0.5 millimeters.C19. The machine of any one of paragraphs C1-C18, wherein the joiningproximity is 0-0.1 millimeters.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A laminate comprising: a first film having afirst plurality of integrally connected, incrementally stretched,elongated corrugations disposed side-by-side, each having: a firstinward facing trough, which has a first trough smallest thickness; afirst outward facing crest, which has a first crest smallest thickness;and a first intermediate portion disposed between the first trough andthe first crest, wherein the first intermediate portion has a firstintermediate smallest thickness, which is less than the first crestsmallest thickness; a second film having a second plurality ofintegrally connected, incrementally stretched, elongated corrugationsdisposed side-by-side, each having: a second inward facing trough, whichhas a second trough smallest thickness; a second outward facing crest,which has a second crest smallest thickness; and a second intermediateportion disposed between the second trough and the second crest, whereinthe second intermediate portion has a second intermediate thickness,which is less than the second crest smallest thickness; a plurality ofattachment areas, wherein each of the attachment areas is directlyconnected to a trough of a corrugation from the first plurality to atrough of a corrugation from the second plurality.
 2. The laminate ofclaim 1, wherein the first intermediate smallest thickness is less thanthe first trough smallest thickness, and the second intermediatesmallest thickness is less than the second trough smallest thickness. 3.The laminate of claim 2, wherein each of the corrugations from the firstplurality is directly connected to only one of the corrugations from thesecond plurality.
 4. The laminate of claim 3, wherein each of thecorrugations from the second plurality is directly connected to only oneof the corrugations from the first plurality.
 5. The laminate of claim1, wherein: the corrugations of the first plurality are discretecorrugations; and the corrugations of the second plurality are discretecorrugations.
 6. The laminate of claim 1, wherein: the corrugations ofthe first plurality are discrete corrugations; and the corrugations ofthe second plurality are continuous corrugations.
 7. The laminate ofclaim 1, wherein: the corrugations of the first plurality are continuouscorrugations; and the corrugations of the second plurality arecontinuous corrugations.
 8. The laminate of claim 1, wherein the firstplurality is only connected to the second plurality by the plurality ofattachment areas.
 9. The laminate of claim 1, wherein each of theattachment areas is substantially continuous along a trough of acorrugation from the first plurality.
 10. The laminate of claim 9,wherein each of the attachment areas is substantially continuous along atrough of a corrugation from the second plurality.
 11. The laminate ofclaim 1, wherein: the first plurality connects to a first uncorrugatedportion of the first film at a first transition; the second pluralityconnects to a second uncorrugated portion of the second film at a secondtransition that is offset from the first transition.
 12. The laminate ofclaim 1, wherein: the first plurality connects to a first uncorrugatedportion of the first film at a first transition; the second pluralityconnects to a second uncorrugated portion of the second film at a secondtransition that is adjacent to the first transition.
 13. The laminate ofclaim 1, wherein for at least some of the corrugations of the firstplurality, a ratio of an amplitude of the corrugation to a wavelength ofthe corrugation is from 0.7 to
 5. 14. The laminate of claim 13, whereinfor substantially all of the corrugations of the first plurality, theratio of the amplitude to the wavelength is from 1 to
 3. 15. Thelaminate of claim 13, wherein for at least some of the corrugations ofthe first plurality, the amplitude is from 1 to 10 millimeters.
 16. Thelaminate of claim 15, wherein for substantially all of the corrugationsof the first plurality, the amplitude is from 1 to 4 millimeters. 17.The laminate of claim 13, wherein for at least some of the corrugationsof the first plurality, a ratio of the wavelength to an overall width ofan attachment area for the corrugation is from 10 to
 50. 18. Thelaminate of claim 17, wherein for at least some of the corrugations ofthe first plurality, the overall width of the attachment area is from0.2 to 1 millimeters.
 20. A disposable wearable absorbent articlecomprising the laminate of claim
 1. 21. A disposable bag comprising thelaminate of claim
 1. 22. A method of forming a laminate, the methodcomprising: incrementally mechanically stretching a first film byengaging at least a first portion of the first film with at least afirst plurality of protrusions to form within the first portion a firstplurality of integrally connected, elongated corrugations disposedside-by-side, each having a trough and a crest; incrementallymechanically stretching a second film by engaging at least a secondportion of the second film with at least a second plurality ofprotrusions to form within the second portion a second plurality ofintegrally connected, elongated corrugations disposed side-by-side, eachhaving a trough and a crest; and while the portion of the first film isengaged with the first plurality of protrusions, and while the portionof the second film is engaged with the second plurality of protrusions,directly connecting the first plurality of corrugations to the secondplurality of corrugations at a plurality of attachment areas, to formthe laminate.
 23. The method of claim 22, wherein the stretching of thefirst film includes forming the first plurality of corrugations, whichare discrete corrugations.
 24. The method of claim 22, wherein thestretching of the second film includes forming the second plurality ofcorrugations, which are discrete corrugations.
 25. The method of claim22, wherein the connecting includes directly connecting the firstplurality to the second plurality at the plurality of attachment areas,such that each trough of a corrugation from the first plurality isdirectly connected to a single trough of a corrugation from the secondplurality.
 26. The method of claim 22, wherein the connecting includesdirectly connecting the first plurality to the second plurality only atthe plurality of attachment areas.
 27. A machine for forming a laminate,the machine comprising: a machine direction and a cross direction; afirst web supply apparatus and a second web supply apparatus, which arethe only web supply apparatus of the machine; a first rotatingpatterning roll, which is downstream from the first web supply apparatusand having a first plurality of rigid, elongated protrusions, each witha tip; and a second rotating patterning roll, which is downstream fromthe first web supply apparatus and having a second plurality of rigid,elongated protrusions, each with a tip; wherein the first roll ispositioned with respect to the second roll such that, as the rollsrotate: the tips of the first plurality are always unmated with the tipsof the second plurality; the tips of the first plurality come withinjoining proximity of the tips of the second plurality, wherein thejoining proximity is 0-5 millimeters.
 28. The machine of claim 27,wherein: each protrusion of the first plurality is a discreteprotrusion; and each protrusion of the second plurality is a discreteprotrusion.
 29. The machine of claim 28, wherein each of the patterningrolls is a solid state formation roll with discrete protrusions.
 30. Themachine of claim 27, wherein each of the patterning rolls is aring-roll.
 31. The machine of claim 27, wherein the first roll isregistered with the second roll such that each of the tips of the firstplurality is aligned with one tip from the second plurality.
 32. Themachine of claim 28, wherein: each protrusion of the first plurality isoriented lengthwise at a first angle from 1-89° with respect to themachine direction; each protrusion of the second plurality is orientedlengthwise at a second angle between with respect to the machinedirection, wherein the second angle is about equal to and opposite fromthe first angle.